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University of Bayreuth, Press Release No. 011/2025 – 03.02.2025

Sustainable 3D Printing with Polyurethane 

Researchers are exploring the use of recyclable thermoplastic polyurethane (TPU) in 3D printing. TPU is intended to replace the resin materials currently used in lattice structures. The Chair of Engineering Design and CAD at the University of Bayreuth is participating in the joint research project DynLatt, funded by the German Federal Ministry of Education and Research (BMBF), alongside medium-sized companies.  

The project structure follows the value chain, starting with material modification and addressing the design and process optimisation of lattice structural components, culminating in the production and validation of a demonstrator. Within this value chain, the Chair of Engineering Design and CAD is responsible for linking design and simulation environments as well as predicting dynamic loads and service life.  

The industrialisation of additive manufacturing is increasingly bringing products like backpack components and helmets to market, where the design freedom of 3D printing is fully utilised. 3D printing offers manufacturers unique design opportunities through layer-by-layer production, enabling distinctive features such as improved damping properties. Increasingly, three-dimensional lattice structures are being used for these purposes. The primary goal of the DynLatt project is to promote sustainable material use in additive manufacturing by employing recyclable thermoplastic polyurethane (TPU) instead of the resin materials commonly used in the serial production of components with highly elastic lattice structures. 

The research project is funded under the BMBF's "KMU-innovativ” initiative with a total of approximately €1.9 million over 36 months, of which around €424,000 is allocated to the University of Bayreuth. 

“TPU is ideal for applications requiring repeated bending or compression, such as in the automotive, transportation, or medical sectors. With 3D printing, TPU gains exciting new design possibilities beyond traditional manufacturing processes,” says Prof. Dr.-Ing. Stephan Tremmel, Dean of the Faculty of Engineering at the University of Bayreuth and project leader for DynLatt at the Chair of Engineering Design and CAD. 

Within the project, the team working under the Chair of Engineering Design and CAD is focusing on advancing simulation and optimisation strategies for lattice structures. Additionally, efficient models are being developed and tested to predict the dynamic behaviour and service life of these structures. Other partners involved in DynLatt include AM POLYMERS GmbH, SQlab GmbH, rpm – rapid product manufacturing GmbH, and SKZ – KFE gGmbH. Together, they are developing an innovative, recyclable product through additive manufacturing with TPU. The insights gained will subsequently be applied to other use cases with associated partners such as AM Solutions GmbH, LuxYours GmbH, and Jack Wolfskin GmbH. 

Prof. Dr.-Ing. Stephan Tremmel

Prof. Dr.-Ing. Stephan Tremmel

Chair of Engineering Design and CAD

Phone: +49 (0)921 / 55-7194
E-mail: stephan.tremmel@uni-bayreuth.de

Theresa Hübner

Theresa Hübner

Deputy Press & PR Manager
University of Bayreuth

Phone: +49 (0) 921 / 55-5357
E-mail: theresa.huebner@uni-bayreuth.de