What is TPE?

Material Properties of TPE

Designing for TPE

• Stabilty: Use thicker walls (2-3 mm minimum) to ensure strength and flexibility.

• Strength: Avoid thin, stiff sections that could snap or tear under stress.

• Geometry: Round corners and smooth transitions; avoid sharp edges to prevent weak spots.

• Overhangs: Keep overhangs below 45° and avoid thin bridges

• Tolerance: Increase tolerances between interlocking parts to account for flexibility.

• Design for compression fittings and easy assembly.

• Support: Use low-density supports to make removal easier without damaging the flexible parts.

• Retraction: Reduce retraction distance and speed to avoid jams and tangling due to the filament's flexibility.

• Print Speed: Print slower (20-30 mm/s) with an extruder temperature of 210°C-230°C and a heated bed at 50-60°C for good adhesion.

• Flexibility: Test parts for stretch and deformation to ensure they perform as needed, especially if flexibility is a key feature.

How to print with TPE - Tips and Tricks

• Low Print Speed: TPE is a flexible filament, so you’ll need to print slower than with rigid filaments. A print speed of 20-30 mm/s is ideal for better quality and smoother extrusion.

• Extruder Temperature: TPE typically prints between 210°C and 230°C depending on the brand. Always check the manufacturer's recommended temperature range for optimal results.

• Heated Bed: Set the heated bed to 50°C to 60°C. TPE doesn't require a high bed temperature, but a warm bed helps with adhesion.

• Direct Drive Setup: Since TPE is flexible and can easily bend, it’s best to use a direct drive extruder rather than a Bowden setup. A direct drive system provides better control over the flexible filament and minimizes the risk of it kinking or jamming.

• Flexible Filament Path: Ensure the filament path from the spool to the extruder is as straight and smooth as possible to reduce the chance of tangling.

• Bed Surface: Use a blue painter’s tape, PEI sheet, or a flexible build plate for good adhesion. These surfaces help prevent warping and allow easy removal after printing.

• Glue Stick or PVA Adhesive: If you're experiencing adhesion problems, apply a light layer of glue stick or PVA-based adhesive to the bed to improve grip.

• Avoid Warping: Flexible filaments like TPE are less prone to warping than other materials, but using a heated bed and good adhesion practices will help maintain the shape of the part during printing.

• Retraction Distance and Speed: TPE tends to tangle and clog if the retraction settings are too aggressive. Reduce the retraction distance to 1-2 mm and the retraction speed to 15-20 mm/s to prevent jams and ensure smooth extrusion.

• Retraction is Optional: Depending on your printer and the complexity of the print, you may even want to experiment with turning retraction off or reducing it significantly for better results.

• Cooling Fans: TPE doesn’t require cooling fans for the first few layers. For the rest of the print, use a low fan speed (20-30%) to help with layer adhesion and to prevent warping or distortion.

• Avoid Over-Cooling: Too much cooling can cause the material to solidify too quickly, leading to print quality issues, so it's important to find the right balance.

Post-Processing with TPE

• Trimming and Smoothing: You can trim or cut your TPE parts using a sharp knife or scissors to get a clean edge, and you can smooth out rough surfaces with fine-grit sandpaper if necessary.

• Stretching and Testing: If your print needs to stretch or flex, ensure you test the flexibility of the part once it’s printed to ensure it meets your functional requirements. TPE can stretch significantly, so it’s important to design accordingly.