3D printing opens up a new world of possibilities- there are so many random things around the house that can be 3d printed. Often, 3d prints are even an improvement from what you can get from the store, or maybe you need something that isn’t even sold in stores. Custom gaskets are often one of those things you can’t easily find at a store. Luckily, 3D printed gaskets are a totally viable option if you have your own 3d printer.
3D printed gaskets can be made by designing the seal on a 3d modeling software (such as Fusion360), choosing a strong & resistant material to print with, printing your gasket, and fine-tuning until it fits perfectly.
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Best Filament for 3D Printed Gaskets
Choosing the right filament is likely the most important thing to consider when making your own 3d printed gaskets. Typically gaskets need to withstand a lot of different elements- be it extreme heat, cold, chemicals, grease, or oil. You don’t want a gasket that is going to degrade due to everyday wear and tear. This makes TPU (thermoplastic polyurethane) the ideal candidate for 3d printing gaskets.
What is Thermoplastic Polyurethane?
NEMA 17 Stepper Gaskets by builttospec
TPU is a type of thermoplastic elastomer. This basically means that it is a “rubber-like” material, made to function like rubber, but not quite rubber. This is a good thing considering natural rubber cannot be melted down like TPU, a necessity for FDM printing.
TPU is highly elastic and flexible. It is resistant to abrasion, impact, and weather- making it highly adaptable to be used in a wide variety of industries such as automotive, construction, and even footwear.1
TPU is comprised of soft and hard segments. The soft segment is made out of polyether or polyester. Polyether-based TPU is most suitable for use in wet environments. Polyester-based TPU is most suitable for oil and hydrocarbon uses. 2
Best TPU Filaments for 3D Printing Seals
Not all TPU filaments are formulated the same. Some have more soft segments, while others have more hard segments. This makes some TPUs more flexible than others (ones with more soft segments are more flexible). Some will be harder and less flexible (ones with more hard segments).
Generally, the softer the TPU, the harder it is to print with. This isn’t usually an issue if you have a direct drive motor, but if you have a 3d printer with a Bowden extruder this can be more challenging to push out the soft flexible filament through the long Bowden extrusion tube.
When you are making something like a gasket, it needs to stand against various different elements. You will want to choose a quality TPU filament. Because of this, the two filament brands below- Hatchbox and NinjaTek- are my favorite TPU filaments to work with.
When shopping for TPU filaments it is helpful to know about shore measurement. Most quality TPU will have a shore measurement that it comes with. Shore is a method of measuring hardness. On the Shore’s hardness scale, TPU’s can be rated from A (flexible type) to D (rigid type). On the A-D scale, it ranges from 0 (soft) to 100 (hard).
Hatchbox TPU
Hatchbox TPU has a shore measurement of 95A, meaning it is a hard, highly resilient, and reliable material. The manufacturer states that their TPU is great for everyday wear and tear on items like phone cases, auto parts, and mechanical seals (aka gaskets). Given that this TPU is on the harder side, it will also work great with a Bowden extruder.
Hatchbox is one of my favorite filament manufacturers they always deliver consistently reliable product and their TPU does not disappoint either.
NinjaTek TPU
NinjaTek has different kinds of TPU filament- NinjaFlex, Cheetah, Armadillo, and Eel. Each one has different properties, with different Shore hardness. While NinjaTek offers top quality TPU filaments, it is important to note not every one will work good with Bowden extruders.
NinjaFlex is a great option for direct drive 3d printers. It has a Shore’s hardness of 85A, making it more flexible than many TPU filaments. If you have a Bowden extruder and still want to try NinjaTek, Cheetah is your best option at a hardness of 95A.
If you want to read more about the properties all NinjaTek filaments have to offer, check out their product comparison guide.
Tips and Tricks for 3D Printing TPU
- If you have a Bowden extruder, make sure that the filament can be used in your printer before buying. Some TPU filaments are too flexible and will only work with a direct drive printer.
- Print slow at 10-20 mm/s. As you get your settings dialed in, you can experiment with printing faster. Printing slowly will ensure that the filament does not get stuck in the tube
- TPU has a different hardness, the softer the TPU, usually the harder to print with.
- With TPU, direct drive is easier than a Bowden extruder. If you have multiple printers, choose your direct drive 3d printer. A direct drive motor is ideal because the filament is less likely to get stuck, and less likely to get pulled/stretched.
- Ventilate the room you are printing in to prevent breathing in toxic fumes.
- Use a dryer box to keep your filament dry, trying to print with wet TPU is difficult and will likely result in print failure. If it does print, not only will it not look as good, but more importantly, it won’t be as strong.
- Many TPU filament brands say that you don’t need to heat the bed. I would ignore this and continue to heat the bed at around 65°C.
Types of 3D Printed Gaskets
TPU is abrasion and chemical resistant, making it’s ability to be used in almost any industry. From old car parts, to lawn mowers, trimmers, electronics parts, stepper motors, and even face respirators.
How to Make 3D Printed Gaskets – 3 Different Ways
NEMA 17 Stepper Gaskets by builttospec
You can make 3d printed gaskets in three different ways: 3d printing a gasket using TPU, 3d printing a prototype gasket to be manufactured, and 3d printing a gasket mold. Keep reading to learn more about each method.
Make a 3D Printed Gasket Using TPU
Making a 3d printed gasket using TPU is likely the most popular method when it comes to 3d printing seals. This method is likely the cheapest and easiest considering you don’t need anything other than your 3d printer and filament.
Step 1. Start by making a 3d model of your gasket.
Step 2. Slice the model using your slicer of choice. Be mindful of the needed settings for the TPU. Be sure to set the print speed to a slow 10-20mm/s. (If you have a direct drive motor you can probably just set the speed to the recommended speed the filament manufacturer state’s).
Step 3. Send your model to the printer.
Step 4. Test out your gasket. If this is your first time using TPU, be patient and expect to tinker with it before it comes out perfect.
3D Print a Prototype Gasket
If you need a custom-made gasket using a specific material that you can’t 3d print with, 3d printing a prototype gasket is a great option.
To do this, you will simply design your custom gasket in a 3d design software, then print the seal using an easy filament to work with (like PLA). You would then see how the gasket fits to make sure the design works, and tinker as needed. Once you have the perfect design, you would find a manufacturer to make your custom gasket.
This option is best if you need a gasket made with a specific material, such as natural rubber. 3D printing a prototype gasket will save you the time and the hassle of getting something made that might not be exactly what you need. Having a prototype available for the manufacturer makes it clear exactly how the custom gasket should be made.
3D Print a Gasket Mold
Customizable Gasket Mold Maker by DrLex
If you need gaskets made of a material like silicone, 3d printing a mold to DIY your own silicone gaskets is the final method we’ll be discussing. This is a great option if you need to make a lot of gaskets, or need something made out of silicone.
This method involves making the gasket mold in your 3d design program of choice. I would make a few different variation to see which comes out the best. When done designing and slicing, print the mold using PLA filament. Once the mold is printed, you will want to mix up your silicone and inject it into the mold using a syringe. After this, you will want to let your silicone cure overnight before removing from the mold. Then, you will want to test out your gasket, to make sure it works properly.
If you want a much more detailed instruction on how to make silicone gaskets using PLA 3d printed mold, check this out.
Conclusion
3D printing your own custom gaskets is a great and viable option. The best filament to print your own gaskets with is TPU, given it’s rubber-like qualities and ability to withstand many different elements. Printing with TPU can have its challenges; it is best to start printing very slowly and make sure your filament is completely dry before you start printing. You can 3d print a gasket using three different methods: 3d printing a gasket mold, 3d printing a gasket prototype, and 3d printing a gasket using TPU.
Want to learn more about designing your own 3d printed gaskets? Check this out.
Happy Printing!