Revolutionizing Flexible Part Development
▌ The Flexible Prototyping Crisis
Product developers in automotive, medical, and consumer goods face critical barriers:
- ✘ 6–10-week waits for silicone/TPU components
- ✘ $12k+ tooling costs for multi-material parts
- ✘ 500-unit MOQs forcing overproduction
- ✘ Limited elasticity control (Shore 30A–80A only)
Our TPU prototypes and double mold prototyping solutions eliminate these constraints:
- ✅ 5-day standard lead times for complex geometries
- ✅ Zero hard tooling investment for 1–300 unit runs
- ✅ Shore 10A–95A range with medical/industrial grades
- ✅ ±0.15mm tolerances via advanced mold systems
▌ Industry-Specific Solutions
1. Medical Device Innovation
- Pain Point: 8-week delays for overmolded surgical grips
- Breakthrough: Overmolded medical device prototypes → ISO 10993-certified parts in 6 days featuring:
- Hard-soft transitions in single assemblies
- Transparent TPU for fluid visualization
- Sterilizable grades (autoclavable to 135°C)
2. Automotive & Robotics
- Challenge: $15k costs for vibration-dampening mounts
- Solution: Industrial TPU bumpers under $100 → UL94 V-0 rated components with:
- Energy return up to 98%
- -40°C to 120°C operational range
- Metal/plastic substrate bonding
3. Consumer Product Development
- Dilemma: 12-week tooling for multi-density shoe soles
- Agile Fix: Custom shoe sole prototyping service → 3D-knit + TPU hybrids in 4 days using:
- Shore 40A/60A/80A zonal gradation
- Dynamic pressure mapping
- Sustainable bio-TPU options
▌ Process Selection Matrix
| Requirement | Optimal Process | Tolerance | Wall Thickness |
|---|---|---|---|
| Ultra-thin membranes (<0.5mm) | Vacuum Casting | ±0.2mm | 0.3–15mm |
| Hard-soft integrations | Double Mold Overmolding | ±0.15mm | 1–25mm |
| High-volume pre-production | Compression Molding | ±0.3mm | 2–50mm |
| Complex internal channels | 3D Printed Silicone Tooling | ±0.25mm | 1–20mm |
Material Innovations:
- Medical: Hemocompatible TPU (USP Class VI)
- Industrial: Oil-resistant/UV-stable grades
- Consumer: Recycled TPU with 95% virgin properties
- Specialty: Conductive/ESD-safe formulations
▌ Low-Competition Keyword Strategy
Target high-intent niches:
- "Low-volume TPU gaskets 72hr" (Maintenance engineers)
- "Multi-material soft robotics molds" (R&D teams)
- "Transparent overmolded buttons" (Electronics brands)
- "Custom drone shock absorbers" (UAV manufacturers)