DFM for 3D Printing: A Practical Design Guide
Wall thickness, tolerances, supports, and hole sizing rules for printable parts.
Read the ArticleTPU 95A 3D Printing Material
Fused Deposition Modeling (FDM) · Flexible
The firmest, most print-friendly TPU - flexible parts with structure.
What Is TPU 95A?
TPU 95A is a high-speed flexible filament that keeps excellent impact resistance and flexibility while being the most print-reliable TPU we offer. It is the go-to for elastic components that still need some rigidity, and it is available for instant quoting.
Thermoplastic Polyurethane (Shore 95A), printed with Fused Deposition Modeling (FDM). Every order is reviewed by our engineering team - no minimum order quantity.
When to choose TPU 95A
Choose TPU 95A when you need a flexible part with real structural definition - one that bends under deliberate force but holds its shape during handling. At Shore 95A, the material feels like a firm rubber: it absorbs impacts, resists abrasion, and returns to shape, but it does not flop or sag like 85A.
TPU 95A is the only flexible material in our auto-quoter, meaning you get instant pricing and faster turnaround. If your flexible-part need is urgent or the geometry is straightforward, 95A is the fastest path to a printed flexible part.
If you need a softer, more rubber-like feel, step down to 90A (medium flex) or 85A (very soft). Those grades are manually quoted and print slower, but deliver genuine softness that 95A cannot match. For parts that need to flex repeatedly under load - living hinges, snap clips - SLS PA11 offers high elongation (40–50%) in a rigid nylon that may be more appropriate than an elastomer.
Material Properties
Representative values - process- and orientation-dependent. Full technical datasheet available on request.
Process
Fused Deposition Modeling (FDM)
Tensile strength
27.3 ± 0.8 MPa
Elongation at break
250–350%
Flexural modulus
Low–medium (elastomer)
Density
1.22 g/cm³
Max build size
245 × 245 × 230 mm
Min wall thickness
1.0 mm
Resolution / layer
150 µm
Relative cost
$$ (1 = lowest, 4 = highest)
Design Guidelines
Plan features to print reliably and assemble cleanly in TPU 95A. Need DFM help?
Min wall
1.0 mm - thicker = firmer feel
Shore hardness
95A - firm flex
Clearance
0.4–0.6 mm - fit & moving parts
Max size
245 × 245 × 230 mm - design for flex
Dimensional tolerances
Dimensional tolerance is ±0.4 mm or ±0.6%. TPU 95A is the most dimensionally accurate flexible material we print - it sags less during printing than 85A or 90A. Functional mating features should still allow 0.4–0.5 mm clearance per side to account for the material's compliance.
Printing notes
TPU 95A prints at 220–240 °C nozzle / 30–60 °C bed at moderate speeds (30–50 mm/s) - significantly faster than softer TPUs. At Shore 95A, the filament is stiff enough to feed reliably even with some Bowden setups, though we use direct-drive for consistency. Retraction can be set to 1.0–2.0 mm without jamming. We dry at 50 °C for 4–6 hours before printing. Supports remove more cleanly from 95A than from softer grades, so moderate overhangs and enclosed features are feasible.
How TPU 95A Compares
TPU 95A alongside related materials.
| TPU 95A | TPU 90A | TPU 85A | ABS | |
|---|---|---|---|---|
| Tensile strength | 27.3 ± 0.8 MPa | 12.5 ± 0.8 MPa | 12.0 ± 0.8 MPa | 33 ± 3 MPa |
| Heat deflection (HDT) | - | - | - | 87 °C @ 0.45 MPa |
| Flexural modulus | Low–medium (elastomer) | Low (elastomer) | Low (elastomer) | ≈ 2,200 MPa |
| Elongation | 250–350% | 300–400% | 330–450% | 10–15% |
| Density | 1.22 g/cm³ | 1.20 g/cm³ | 1.18 g/cm³ | 1.05 g/cm³ |
| Relative cost | $$ | $$ | $$ | $$ |
When to Use TPU 95A
Where TPU 95A fits, where it doesn't, and what to use instead.
Flexible functional prototypes
Auto-quotable and fastest to print among TPUs (30–50 mm/s), so iterating on flexible part geometry takes days instead of the week-plus timeline of softer grades.
EngineeringGrips, handles, and bumpers
27.3 MPa tensile - nearly double 85A/90A - means grip surfaces resist cuts and gouges that softer TPUs would sustain in industrial handling.
Consumer ProductsProtective device housings
Absorbs and distributes impact energy through elastic deformation; a 2 mm wall survives repeated 1.5 m drops onto concrete without cracking.
Consumer ProductsFirm seals and gaskets
Shore 95A provides enough rigidity to maintain seal profile during installation while still compressing 10–15% for effective flange conformance.
EngineeringWearable enclosures and straps
Firm enough to hold electronics and circuit boards in position, flexible enough to wrap around wrists and limbs without rigid pressure points.
Medical DevicesStrengths
- Firmest TPU in the catalog at Shore 95A - holds shape under gravity and during handling, unlike softer 85A/90A grades that droop
- Only flexible material in the auto-quoter: instant pricing and fastest turnaround for straightforward flexible-part orders
- Tensile strength of 27.3 MPa - nearly 2x the 85A grade - with 250–350% elongation that still provides genuine elastic recovery
Keep in mind
- Noticeably less soft than 85A/90A - feels like a firm rubber, not a cushion; step down to 90A or 85A for soft-touch applications
- Still an elastomer with ±0.4 mm tolerance - not suited for precision fits or structural load paths; use rigid materials where positional accuracy matters
- Design mating interfaces with 0.4–0.5 mm clearance per side to account for material compliance under assembly force
Finishes & Colors
Finishing options and in-stock colors for TPU 95A.
Standard
As-printed; matte flexible surface.
Best for: Functional flexible parts
In-Stock Colors
Natural
Black
Custom colors and dyeing available on request. Contact us for options.
TPU 95A FAQ
95A is the most print-reliable flexible material we stock, so it runs through our instant Auto-Quoter. Softer 85A/90A grades are quoted manually to ensure print success.
Yes. It absorbs impact well and resists abrasion, which makes it well suited to bumpers, grips, and protective parts.
TPU 95A absorbs and distributes impact energy through deformation, then returns to shape. ABS resists deformation but can crack under sharp impact. For repeated-impact applications (bumpers, drop-protection), TPU 95A outlasts ABS. For structural rigidity with moderate impact resistance, ABS is better.
Yes. TPU 95A is widely used for protective phone and device cases. It absorbs drops, resists scratches, and has enough rigidity to snap on and off. Design wall thickness of 1.5–2.0 mm for adequate protection.
TPU has moderate chemical resistance - it handles oils, greases, and dilute acids and bases well. It is not resistant to concentrated solvents like acetone or MEK. For chemical-handling parts, MJF PP (polypropylene) offers broader chemical resistance.
We hold ±0.4 mm or ±0.6% - the tightest of any TPU we print. For snap-fit features, allow 0.4–0.5 mm clearance per side. The material's compliance means press-fit connections need tighter interference than with rigid plastics.
TPU 95A is an elastomer - it stretches and rebounds. PP is a semi-rigid plastic with excellent fatigue life for thin-web living hinges. Choose TPU 95A for parts that need to absorb impact and deform elastically. Choose PP for parts that flex at specific hinge points but stay rigid elsewhere.
Printed TPU 95A is slightly weaker in the Z-axis than injection-molded TPU due to layer adhesion, but XY properties are comparable. For prototype and low-volume flexible parts (1–100 units), printed TPU is far more cost-effective than tooling for injection molding.
Technical Documents
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