BASF 3D Ultrafuse TPU 64D Fused Fillament
- Название продукта: BASF 3D Ultrafuse TPU 64D Fused Fillament
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- BASF 3D Ultrafuse TPU 64D Fused Fillament is typically used in formulations when mechanical property requirements and processing parameters must be controlled within specific ranges.
| Код ТН ВЭД | 481381 |
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In custom sports footwear manufacturing, the 64D shore hardness grade is selected for components that must resist buckling and cut growth under repeated flexural loading, not for midsoles or cushioned insoles. The material is printed into heel counters, cleat plates, and orthotic posting shells on direct-drive fused filament machines fitted with 0.4 mm hardened nozzles. The manufacturer’s processing window of 225–245°C extrusion, 40–60°C bed, and 20–40 mm/s linear speed is maintained. Filament is dried at 60°C for 4 h in a dry-air convection dryer to residual moisture below 0.02% before processing. The toolpath uses 0.16 mm layer height, irregular seam placement, and a perimeters-to-sparse-infill ratio of 6:0; the interior is fully dense through concentric perimeters, eliminating void channels along which cut growth propagates in flex trials. Annealing at 80°C for 2 h between flat aluminium plates reduces interlayer residual stress but produces 0.3–0.5% XY shrinkage that must be offset in the CAD model. Compliance under ISO 17707:2005 is evaluated after 30,000 flex cycles; fully dense unfilled 64D TPU prints typically show no cut growth above 4 mm in the 1.0 J puncture test, whereas sparse infill below 60% fails by interlayer cleavage. The terminal components are heat-formed to the last with 2 mm wall thickness and bonded using solvent-free polyurethane adhesives.
Can Fused Filament Fabrication Produce Compression-Set-Stable Static Seals from 64D TPU?
For vacuum plates and low-pressure pneumatic tooling, the filament is formed into static gaskets, backup rings, and dust seals only where continuous dynamic lip flexing is not required. The bulk hardness of 64D places this grade above the range normally selected for lip seals; a static face seal can operate under uniform compression of 15–25%, but a dynamic energised seal is likely to leak because the stiff polymer cannot follow piston rod eccentricity. Successful face seals are printed with 0.15 mm layer height, 100% rectilinear infill, and randomised seam placement. Retraction is disabled on travel moves longer than 2 mm because filament buckling in the extruder gear creates local density defects at the weld. The sealing surface is oriented parallel to the XY build plane so that surface roughness Ra remains below 6 µm without mechanical polishing. Compression set is determined according to ASTM D395-18 Method B at 70°C for 24 h under 25% constant deflection. Data for injection-moulded TPU of equivalent hardness indicate compression set in the 25–40% range; FFF porosity can raise this value by 5–10 percentage points unless the part is annealed at 80°C for 2 h. The limiting temperature for continuous service is 70°C in dry air. High humidity above 85% RH combined with temperature over 60°C accelerates hydrolytic chain scission and must be avoided. The final component is a square-edge vacuum cup seal for CNC woodworking vacuum tables, clamped at 25% nominal compression with an aluminium torque plate.
Conveyor Guide Rails and Low-Load Wear Strips
On bottling and packaging lines, the filament replaces machined ultrahigh-molecular-weight polyethylene where periodic contact with glass bottles and stainless steel chain guides demands controlled abrasion and noise damping. The part is printed with a 0.6 mm hardened nozzle, 0.25 mm layer height, and 8 perimeters as a fully dense wear shell. Extrusion is set at 235–245°C and bed temperature at 50–60°C; chamber temperature is held at 35°C to reduce warpage in guide rails longer than 300 mm. The wear track is deliberately oriented parallel to the XY plane because the top surface has fewer weld boundaries than vertical side surfaces. Relative volume loss measured on injection-moulded TPU with 64D hardness commonly falls between 20 mm³ and 40 mm³ under DIN ISO 4649-A with 10 N load. Build-orientation-specific wear data for FFF parts are not fully published; however, side-wall surfaces show measurable abrasive loss after 20–40% fewer cycles than top surfaces in comparative production trials. Coefficient of friction against polished steel is in the 0.5–0.7 range under dry conditions, so low-load guides should use starved food-grade grease at 0.03 g/m² or a UHMWPE tape facing instead of relying on TPU alone. Continuous contact temperature above 60°C softens the wear track and increases creep. The terminal product is a snap-in guide rail for PET bottle necks, using 2 mm wall thickness and 4 mm mounting bosses printed into the rear face.
| Application segment | Governing standard | Test or condition | Operational boundary |
|---|---|---|---|
| Footwear structural inserts | ISO 17707:2005 | 30,000 flex cycles | wall thickness ≥2 mm |
| Static vacuum seals | ASTM D395-18 Method B | 24 h/70°C at 25% deflection | ≤70°C dry air |
| Conveyor wear strips | DIN ISO 4649-A | 10 N, 40 m path | dry friction coefficient limited |
| Robotic soft jaws | ISO 604:2002 | stress at 10% compressive strain | force limited by face area |
| Cable strain relief | IEC 62368-1:2023 | pull-out after 85°C/85% RH ageing | bend radius ≥8× cable OD |
| Impact housings | IEC 60068-2-31:2008 | 1 m surface drop | sparse infill below 60% not permitted |
When Machined Urethane Soft Jaws Are Replaced by Perimeter-Dense Printed Tooling
Application for robotic handling of painted metal, glass, and polished aluminium uses conformal gripper jaws printed from unfilled 64D TPU, where the plasticised surface prevents marring while maintaining geometric repeatability. The contact face is positioned in the XY plane so that the top surface of the print becomes the working interface; this reduces the ridge texture that a vertical print would present. A toolpath with 5 perimeters and 25% triangular sparse infill is selected because a fully solid jaw transmits excessive force without the localised deformation needed for surface adaptivity. Indentation testing under ISO 868 records a lower effective Shore D reading on the sparse-fill side, typically 52–58, while the perimeter band remains near 64. The compressive stress at 10% strain is measured according to ISO 604:2002; production jaws with 600 mm² contact area are limited to 220–260 N clamping force before deformation exceeds 10% and releases the part. Sharp edges on the workpiece are eliminated from contact zones because the printed TPU has lower tear resistance than machined cast urethane. The final end-of-arm component is a 72 mm long two-finger gripper jaw set with a conformal negative pocket, used for glass headlamp lens placement. It is constrained to 40°C ambient operation and excluded from exposure to ketone-based cleaning solvents.
Unlike softer thermoplastic polyurethane grades, the 64D filament is selected for cable strain relief clamps and robotic harness retainer brackets only where pull-out resistance and low hysteresis outweigh soft grip. The terminal geometry is a split grommet shell with 3 perimeters, 100% infill, and 0.20 mm layer height. The axial load path is aligned with the XY build plane because Z-direction tensile strength of FFF TPU can be 30–50% lower than XY values. A bend radius of at least 8× the cable outer diameter is maintained in the strain relief transition, and the printed shell is clamped around the cable jacket without secondary adhesive. Slippage force after 24 h of environmental conditioning at 85°C/85% RH is evaluated according to the host device standard, commonly a 100 N pull-out criterion for industrial control panels. Repeated flexure is limited to small-angle vibrations below 10° and 1 Hz because fatigue cracks initiate at layer weld lines; for higher-angle dynamic service, a printed part without post-annealing fails by delamination within 10³–10⁴ cycles. The processed part is a cable entry grommet for a robotic controller enclosure, used in combination with a nylon locking nut that imposes only radial compression. No silicone-based lubricants are used during assembly because silicone migration lowers surface friction and can reduce retention force.
Impact Housing Performance Is Governed by Interlayer Diffusion, Not Bulk Hardness
Protective shells for handheld instruments, drone arm covers, and actuator housings rely on the material’s high elongation at break, but the limiting design variable is the strength of the weld between adjacent layers. FFF parts printed from unfilled 64D TPU at 0.15 mm layer height, 235°C extrusion, and 1.05–1.10 extrusion multiplier exhibit improved interlayer diffusion. The print chamber is held at 30–40°C and the part is shielded from drafts to maintain uniform cooling; local airflow from a part-cooling fan above 20% duty cycle lowers the previous layer temperature below the glass transition region and creates a brittle weld. A 3 mm shell with 100% infill is used where drop resistance is specified; sparse infill below 60% reduces impact energy absorption disproportionately because the thin perimeter shell buckles and then tears along the weld lines. Impact testing follows the surface-drop method of IEC 60068-2-31:2008 from 1 m onto a 20 mm thick oak panel. Build orientation is selected so that the expected impact point is not a side surface interrupted by the z-seam. Post-annealing at 80°C for 2 h enhances weld strength but may distort unsupported thin sections, so fixtures are required. Exposure to glycols and automotive coolants is limited to intermittent splash, not continuous immersion, because TPU can absorb 1–2% moisture at equilibrium and soften at the weld. The terminal component is a 160 mm × 90 mm × 35 mm drone arm cover with 2 mm nominal wall thickness, using threaded brass inserts placed after printing with 0.2 mm radial interference.
Sports protective inserts fabricated from 64D TPU are produced as shin guard plates, forearm impact caps, and ski boot toe reinforcements rather than soft padding. The part is printed with 0.20 mm layer height, 4 perimeters, and 40% gyroid sparse infill. Gyroid infill is selected because it distributes impact stress along three axes and avoids the planar buckling that hexagonal infill shows after repeated transverse impact. The outer surface is oriented upward on the build plate to create a smooth cosmetic face. A 2.5 mm nominal wall is used for adult forearm protection; thinner 1.5 mm walls are restricted to low-impact training environments because the printed shell loses rigidity below that section. Impact attenuation is assessed under EN 1621-1:2021 for limb protectors; transmitted force is recorded after conditioning at 23°C and 50% RH. Published data for this specific FFF configuration are limited; injection-moulded TPU of similar hardness generally transmits below 35 kN at 50 J impacts, but FFF weld lines can create local stiff spots that increase transmitted force by 10–20%. The terminal product is a custom ski boot toe cap with a dual-durometer adhesive foam liner, bonded with an aliphatic isocyanate polyurethane adhesive. It must not be exposed to methanol-based ski wax removers, which swell the TPU and delaminate the adhesive line.
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BASF 3D Ultrafuse TPU 64D is a thermoplastic polyurethane feedstock for fused filament fabrication, supplied on spools in nominal diameters of 1.75 mm and 2.85 mm. The product is part of the BASF 3D Printing Solutions Ultrafuse portfolio and is formulated to a Shore hardness of 64D when tested under ISO 868. This hardness class places the material above conventional flexible TPU of Shore 95A and below rigid polyamide or polycarbonate feedstocks. Manufacturer-published density is approximately 1.21 g/cm³ under ISO 1183-1. The filament is used for functional parts, jigs, vibration-damping mounts, housings, and protective covers in which a balance of stiffness, impact recovery, and chemical resistance is required. Because the polymer is a thermoplastic polyurethane, processing behaviour differs from amorphous PLA and brittle ABS. Moisture control, extruder drive pressure, and filament path constraint become dominant process variables.
The Ultrafuse TPU 64D grade is not a general-purpose flexible filament. Its hardness class and melt rheology place it in a narrow processing band that demands calibration of retraction, temperature, and extrusion multiplier. Manufacturer technical data sheet values should be consulted for lot-specific batch data. Published data for this specific configuration is limited for some dynamic mechanical properties, so design allowables require coupon-level testing under the relevant ISO or ASTM method.
Which Processing Variables Change the Extrusion Envelope?
Nozzle temperature, volumetric throughput, and retraction interact strongly in Shore 64D TPU. The manufacturer-specified extrusion temperature range is generally 220 °C to 240 °C. Below 220 °C, interlayer weld strength tends to decline because polymer chain diffusion across the layer interface is incomplete. Above 240 °C, the melt may begin to undergo urethane bond cleavage if residence time is prolonged. A standard brass hot end with a 0.4 mm nozzle requires an extrusion multiplier calibrated to avoid overpressurization of the melt chamber. Feed path limitations are more severe than for rigid PLA but less severe than for Shore 95A TPU because the 64D hardness reduces filament buckling under compressive load.
Direct-drive extruders with dual-drive gears and constrained filament paths are preferred. On these systems, retraction distances of 0.8 mm to 1.5 mm are typical starting values. In Bowden configurations with tube lengths greater than 300 mm, retraction distances of 2 mm to 4 mm are often required to compensate for filament compression and elastic recovery. Print speeds above 60 mm/s may reduce interlayer adhesion because the melt spends less time in the weld zone. Volumetric flow rate ceilings are hot-end-specific; published data for this exact configuration is limited. The practical approach is to calibrate linear advance and avoid rapid speed changes that create pressure oscillations in the nozzle.
Melt viscosity is highly shear-rate dependent. At typical FFF wall shear rates of 100 s⁻¹ to 1000 s⁻¹, the viscosity falls sufficiently for extrusion through a 0.4 mm nozzle, but at lower shear rates in the melt chamber, the residence time determines degradation risk. Exact rheological data are not published in the product datasheet, so pressure advance constants cannot be transferred directly from PLA or ABS profiles. The hot-end thermistor should be accurate within ±5 °C because the processing window is narrow.
Mechanical property values reported for Ultrafuse TPU 64D are generated on printed specimens, not injection-moulded plaques. Under ISO 527-2, typical tensile strength at break is approximately 34 MPa, and elongation at break is approximately 430%. The tensile modulus is approximately 80 MPa. These values vary with print orientation, layer height, nozzle temperature, and moisture content. Hardness is measured under ISO 868, while tear resistance is reported under ISO 34-1. Abrasion resistance is characterized using ISO 4649. The product exhibits higher indentation resistance than Shore 95A TPU, but its tensile modulus remains far below that of glass-filled nylon or polycarbonate. This combination supports applications in which repeated flexural cycles must be absorbed without brittle fracture. The numerical ranges should not be used for design allowables unless confirmed with in-house printed test coupons per ASTM D638-14 or ISO 527-2.
Layer orientation anisotropy remains a measurable limitation. The z-direction tensile strength is lower than the x-y plane value because layer fusion is incomplete at normal print speeds. Users who require higher z-strength may reduce layer height to 0.10 mm or increase nozzle temperature within the recommended range, but this increases build time and can alter surface appearance. Published data for the exact z-strength reduction factor is limited for this grade. Notched impact values, if required, should be measured under ISO 180 or ASTM D256-10 because layer interfaces affect crack initiation.
When Moisture Uptake and Spool Conditioning Are Not Managed
TPU absorbs atmospheric moisture. Pre-drying at 80 °C for 4 h in a desiccant dryer is recommended before processing. Spools exposed to relative humidity above 60% for more than 24 h may show surface bubbles, nozzle popping, and reduced interlayer fusion. The defect mechanism is hydrolysis of the urethane group. At melt temperatures above 220 °C, absorbed water converts to steam inside the hot end, causing filament sputter and inconsistent extrusion. The product should be stored in a sealed container with desiccant when not in use. After drying, the filament can be processed in open air for a limited window; this window shortens in humid environments.
Drying time should not exceed the manufacturer stipulation because prolonged exposure to 80 °C can soften the filament on the spool if hot spots develop. Induction or vacuum drying may be used if the temperature is controlled. In production environments where multiple spools are stored near a printer enclosure, moisture management is a practical bottleneck. A desiccant dryer with a dew point below −40 °C is more effective than a simple heated chamber at maintaining low moisture content during long builds.
| Parameter | Value | Condition |
|---|---|---|
| Nozzle temperature | 220–240 °C | brass nozzle, 0.4 mm |
| Bed temperature | 20–60 °C | glass or PEI surface |
| Print speed | 15–60 mm/s | direct-drive |
| Retraction distance | 0.8–1.5 mm | direct-drive |
| Retraction distance | 2–4 mm | Bowden, >300 mm |
| Drying | 80 °C, 4 h | desiccant dryer |
| Cooling fan | 20–50% | single part |
These values are starting points. Actual settings must be developed on the target machine because heater cartridge wattage, thermistor calibration, and hot-end thermal mass shift the required setpoint.
Filament Diameter, Ovality, and Feed-Gear Interaction
Filament diameter variations above 0.05 mm can produce periodic over- and under-extrusion in a fixed-displacement extruder. The product is supplied with dimensional tolerances, but users should verify incoming spools with a laser micrometer. A variation of ±0.03 mm is common for industrial-grade filament. If measured ovality exceeds 0.02 mm, the effective cross-sectional area changes by more than 2%, altering volumetric flow rate. This is particularly important for Shore 64D TPU because its elastic response can magnify feed-gear marking.
Idler pressure must be set low enough to avoid shaving the filament surface. Excessive pressure creates dust that accumulates in the drive gear and can lead to under-extrusion. Hardened steel or stainless steel drive gears are preferred over brass because TPU can be abrasive after pigment addition. The spool should rotate freely to avoid filament tangling. A spool holder with a bearing-supported hub reduces feed resistance in long prints.
Chemical resistance of TPU is influenced by the ratio of hard segment to soft segment. Ultrafuse TPU 64D is used in pneumatic connectors, protective housings, and wear strips that contact oils and non-polar solvents. For prolonged immersion in strong acids, chlorinated solvents, or brake fluid, compatibility tests under ISO 175 or ASTM D543-14 are required. The grade is generally more resistant to non-polar oils than soft TPU, but swelling may still occur with high-aromatic fuels. In comparison with standard PLA, the product retains elasticity after repeated loading. Compared with ABS, TPU 64D does not require a heated chamber and has lower volatile emission during printing. Compared with nylon, it avoids the severe moisture sensitivity that requires immediate drying but still benefits from drying at 80 °C.
For impact-absorbing applications, the Shore 64D hardness class provides higher energy return than very soft TPU but lower damping than cellular elastomers. The material is not a replacement for silicone rubber in high-temperature sealing applications. Continuous-use temperature is generally below 100 °C for printed parts under load. The Vicat softening point is listed in the current manufacturer technical data sheet under ISO 306; users should verify the method and loading because printed specimens may soften earlier than injection-moulded plaques.
Regulatory data sheets for REACH and RoHS should be requested per lot. For food contact or medical use, the specific grade and colorant must be evaluated against the relevant food-contact or biocompatibility standards. BASF 3D Ultrafuse TPU 64D is not supplied with universal food-contact certification.
Fused Filament Fabrication Settings Alone Do Not Determine End-Use Performance
Post-print annealing is not typically required for TPU 64D, but stress relief at 60–80 °C for 30–60 min may reduce residual stress in thick sections. High-temperature annealing above the Vicat softening range is not advised because dimensional distortion occurs. The filament is compatible with water-soluble support in some dual-extrusion setups, but the support interface may weaken because TPU does not achieve high melt temperature with most breakaway support materials. In single-extrusion printers, overhangs above 45° require support or careful cooling. Excessive part cooling fan settings can create filament solidification before layer spreading, reducing weld strength. Fan speeds of 20–50% are typical starting points.
Comparing this grade with other Ultrafuse TPU products, the 64D hardness class is selected when a part must withstand point loads and abrasion without the floppy deformation of Shore 95A. The trade-off is lower elongation at break and reduced low-temperature flexibility. For living hinges and highly elastic straps, softer grades remain more appropriate. For rigid structural components, glass-filled PA or PC provide higher modulus but lack the energy return of TPU. The product occupies an intermediate position that is useful when both dimensional stability and impact recovery are required. Published data for the specific configuration of printed TPU 64D in dynamic fatigue is limited; rotating-beam or flexural fatigue tests must be performed on the final print orientation.
PETG and TPU 64D both offer chemical resistance but differ in deformation behaviour. PETG may yield under impact, while TPU 64D undergoes elastic deformation and recovery. This difference is measurable through tensile elongation at break and low-strain modulus. The TPU 64D grade exhibits a yield-like transition at higher strain but generally does not form whitening or stress cracking as PETG can. In flame-retardant enclosures, TPU 64D is not a substitute for UL 94 V-0 rated materials unless the specific grade is rated and certified.
Industrial FFF printers with heated build chambers are not strictly required, but a chamber temperature of 30–40 °C can improve layer adhesion in large parts. At chamber temperatures above 50 °C, the filament may soften before entering the extruder, causing feed failures. This is a practical boundary for enclosed professional machines. Changing the nozzle from 0.4 mm to 0.6 mm reduces backpressure and increases flow rate for the same feed rate, but layer adhesion may decline if the temperature is not increased accordingly. Firmware pressure advance must be recalibrated for each nozzle size because the elastic response of the melt differs.
