SYNTHЭD+ PUprint

As a specialist in thermoset Polyurethane resin formulation, Synthene’s strength is to benefit from its extensive expertise in the fabrication of rapid prototyping resins and injection-moulding PU rubber.

This opens the door to adapting injection and molding elastomers into 3d-printable PU products.

We obtain mechanically strong and functional parts, with a high structural integrity. The PU part is as strong as a molded part, that can be used not only as a prototype but also as a final part with high durability.

The PUPrint materials are thermoset polyurethane elastomers.

Unlike TPU (Thermoplastic Polyurethane), thermoset materials benefit from a very stable chemical structure, providing high performance and durability.

The chemical nature of thermoplastics and thermoset plastics is different. When exposed to high temperatures, TPU are subject to melting. A thermoset polymer will often show a higher temperature resistance. When exposed to very high heat, the material will be degraded, but is not likely to melt.

This range of thermoset PU for printing is completely different from Stereolithography or Digital Light Processing.

With the technology of Material Extrusion (MEX), a two-component liquid polyurethane is printed on the support with a 3D-printer.

The deposition of material, layer after layer, involves a chemical reaction between each stratum, creating a strong bonding and adhesion. The 3d-printed part is therefore perfectly isotropic. Its durability is remarkable compared to photopolymerizable systems like SLA or DLP.

Additive Manufacturing opens the field of possibilities in terms of project realization.

First, it allows one to create an infinite combination of shapes, without the restrictions imposed by injection-moulding.

It is also a way to get rid of the tooling material. An aluminium mold often represents a high cost in a project budget, and often involves a certain rigidity in terms of design and flexibility. A silicone mold allows more possibility to change, but has a limited lifetime. 3D-printing polyurethane is therefore a more cost-efficient solution, that allows more creativity in the testing process and in the production phase.

The advantages that Additive Manufacturing brings to the equation are endless. The production process is more environmental-friendly with no tooling material, no release agent and almost no waste: each drop of PU material is carefully used during the printing process. In terms of product economy, it is also possible print lighter parts, by designing an STL file with less material inside the core of the part.

The use of a 3d-printer can indeed allow specific shapes that are technically not possible with the process of injection moulding, thus increasing the possibilities tenfold, without compromising the mechanical performance.

This unique technology is the fruit of a close partnership between Synthene and Lynxter, a French company that manufactures 3D printers capable of printing polyurethane and silicone. Our PUprint resin is specifically formulated for their machines. The printing process perfectly adapts to the deposition of two-component liquid materials, with the possibility to add a support material.

The nature of a thermoset polyurethane provides a comprehensive set of assets for the realization of strong and functional 3d-printed parts.

The chemical reaction between each layer ensures better mechanical resistance