Challenges on extrusion-based additive manufacturing of thermoplastic polyurethane

Fused filament fabrication (FFF) offers rapid production with user-friendly operation and cost-effectiveness, yet challenges in printing with thermoplastic polyurethane (TPU) persist. This study identifies causes of print defects in FFF-TPUs and their relation to process parameters, by visually analysing samples produced with various TPU materials. Extrusion temperature, printing speeds, filament cooling, overlap, and extrusion flow are subject to evaluation. Common issues include filament entanglements, under-extrusion, stringing, or geometric deviations. Among other approaches, results highlight the importance of slow, constant print speeds and careful optimization of extrusion temperature.