Effect of Process Parameters on the Hardness of 3D-printed Thermoplastic Polyurethane that Includes Foaming Agent

Recent progress in Material Extrusion-based Additive Manufacturing (MEX) has introduced active foaming agents in filaments composition, thus allowing for the tuning, by various process parameters, the hardness and the mechanical behavior of 3D-printed parts. In case of thermoplastic polyurethane (TPU) filaments, these advances significantly broaden the range of applications, particularly in the domains of comfort and orthotics (wrist-hand orthoses, insoles), offering the dual benefits of design flexibility inherent in MEX and the comfort of lightweight and customizable structures. However, the field is still in its early stages, with only a limited number of research efforts dedicated to characterizing these novel materials. In this context, this study is focused on determining the influence of printing temperature (190�C, 220�C, 240�C), infill density (25%, 35%, 45%) and infill pattern (honeycomb, gyroid) over the hardness of cylindrical specimens made of Colorfabb varioShore TPU. A comprehensive methodology of calibration is also presented as mandatory for obtaining good quality and accurate products by establishing correlations between flow rate and printing temperatures. The findings showed that the printing temperature is the most relevant factor impacting the hardness of varioShore TPU prints. At a printing temperature of 190�C, which corresponds to less foamed prints, the honeycomb infill yielded higher hardness compared to the gyroid infill, but the difference was not significant. Also, at 220�C and 240�C, the mean values of hardness remain relatively consistent, regardless of infill density and pattern.