How to Print with VarioShore TPU: Ultimate Guide for Flexible, Lightweight 3D Printing

3D printing with flexible materials can open a world of creative possibilities. From producing soft-touch, rubber-like parts to designing lightweight foams, flexible filaments add a unique dimension to 3D printing. One of the standout materials in this category is VarioShore TPU by ColorFabb, known for its remarkable flexibility and variable density. Unlike standard thermoplastic polyurethanes (TPUs), VarioShore TPU can be manipulated to produce foamy textures, giving it a sponge-like quality perfect for projects that require both resilience and softness.

In this guide, we'll dive into everything you need to know about printing with VarioShore TPU—from understanding its unique properties to mastering print settings, techniques, and troubleshooting tips. By the end, you'll have the confidence and knowledge to produce outstanding results with this innovative filament.

What is VarioShore TPU?

Unique Properties of VarioShore TPU

VarioShore TPU is a highly adaptable flexible filament developed by ColorFabb. This material is a type of thermoplastic polyurethane that can be foamed during the printing process, enabling users to control its density by adjusting temperature settings. When heated, VarioShore TPU expands, reducing its weight by up to 50% and providing a soft, foam-like structure. This versatility makes it ideal for creating a range of textures and densities within the same material.

Unlike typical TPU filaments that provide a standard flexible output, VarioShore offers adjustable softness and density, making it suitable for applications like shoe insoles, custom grips, shock-absorbing parts, and more. This ability to control density adds a whole new layer of functionality, setting VarioShore apart from other flexible 3D printing materials on the market.

Key Benefits of VarioShore TPU

1. Variable Density: By adjusting the printing temperature, you can create different levels of foam expansion, allowing for parts with varying degrees of softness and flexibility.
2. Lightweight: VarioShore can reduce part weight by up to 50%, making it ideal for applications where reducing mass is essential.
3. Exceptional Flexibility: As a TPU-based filament, VarioShore provides excellent elasticity and durability.
4. Thermal Stability: It retains flexibility across a wide temperature range, making it suitable for parts exposed to changing environmental conditions.

Ideal Applications for VarioShore TPU

VarioShore TPU’s unique properties make it suitable for a variety of functional and creative applications, including:

• Shoe Insoles and Orthopedic Supports: Lightweight and cushioned, perfect for wearable comfort.
• Sports Equipment Grips: Offers shock absorption and a comfortable grip.
• Drone Landing Pads: Lightweight and shock-absorbent, protecting drones upon landing.
• Custom Gaskets and Seals: Flexibility and durability for industrial parts.
• Soft Touch Parts: Items like handles, ergonomic grips, and tactile surfaces that benefit from a soft feel.

How to Print with VarioShore TPU

To unlock the full potential of VarioShore TPU, you need to carefully adjust print settings and techniques. Below, we’ve outlined the best practices and recommended settings for successful VarioShore printing.

1. Recommended Printer Setup

Direct Drive Extruder

VarioShore TPU is a flexible filament, and as such, it performs best with a direct drive extruder. Direct drive systems minimize the filament path from the extruder to the nozzle, reducing the risk of filament bending or buckling, which is common with flexible materials in Bowden extruders.

Nozzle Size

While a standard 0.4 mm nozzle works well, larger nozzle sizes (e.g., 0.6 mm) are beneficial for achieving consistent results with VarioShore TPU, particularly when printing with thicker layers. The larger nozzle helps reduce pressure build-up, improving extrusion and reducing clogging.

Heated Bed

VarioShore TPU adheres well to a heated bed set between 50°C and 60°C. Ensure the bed is clean, and consider using a build surface like glass or PEI to enhance adhesion. If you experience warping, consider using a bit of glue stick or painter’s tape for better adhesion.

2. Optimal Temperature Settings

Extruder Temperature

VarioShore TPU’s unique foaming effect is temperature-dependent. Higher temperatures (around 230°C to 250°C) result in more foaming, creating a lighter, softer structure. Lower temperatures (180°C to 200°C) produce denser, less foamy prints. Here’s a guide for adjusting density with temperature:

• 180°C - 200°C: Minimal foaming, denser output, good for rigid parts.
• 200°C - 230°C: Moderate foaming, semi-flexible parts.
• 230°C - 250°C: Maximum foaming, lightweight and soft-touch results.

Experiment within this range to achieve the desired balance of density and flexibility.

Bed Temperature

A bed temperature of 50°C - 60°C is generally sufficient to prevent warping and promote good adhesion. Higher bed temperatures are typically unnecessary, as TPU does not contract significantly when cooling.

3. Print Speed and Retraction Settings

Print Speed

Flexible filaments like VarioShore TPU should be printed at slower speeds. A good starting point is 20 - 40 mm/s, which allows the extruder to handle the filament more effectively without jamming or under-extruding.

Retraction Settings

Minimal retraction is crucial with VarioShore TPU. Excessive retraction can lead to filament jams or tangling within the extruder. Set retraction distance to 1 mm or less and keep retraction speed low. Some printers may even perform better with retraction disabled.

4. Layer Height and Print Flow

Layer Height

A layer height of 0.2 mm is a good compromise between print speed and detail for VarioShore TPU. However, you can go as low as 0.1 mm if high detail is required, or increase it to 0.3 mm if speed is a priority.

Print Flow

Adjusting the flow rate can help in achieving consistent extrusion, especially when aiming for a foamy texture. A flow rate between 90% and 100% is generally recommended, but this can be fine-tuned based on your specific printer setup and desired texture.

Troubleshooting Common Issues with VarioShore TPU

Printing with VarioShore TPU can present unique challenges. Here are solutions to some common issues:

Issue: Stringing and Oozing

Solution: TPU materials are prone to stringing due to their elasticity. Lower your print temperature slightly and reduce print speed to minimize stringing. Additionally, adjust retraction settings—reducing the retraction distance or speed can help.

Issue: Under-Extrusion

Solution: Ensure that the filament path is clear, and clean the nozzle if necessary. Increasing the extrusion temperature slightly can improve flow, especially when printing at higher speeds.

Issue: Clogging in the Extruder

Solution: Flexible filaments are more likely to buckle and clog. To prevent this, ensure the extruder is well-tensioned and avoid aggressive retraction. Using a larger nozzle can also alleviate pressure build-up, reducing clogging risk.

Issue: Warping

Solution: While TPU generally adheres well, improper bed adhesion can cause warping. Use a heated bed and add an adhesive like glue stick or painter’s tape to improve adhesion. Lowering the initial layer height can also enhance bed adherence.

Tips for Achieving the Best Results with VarioShore TPU

1. Experiment with Temperature: Temperature is key to achieving the right texture with VarioShore TPU. Test different temperatures on small prints to find the ideal setting for your specific application.
2. Use Slow Print Speeds: Printing too quickly can cause issues with flexible filaments. Stick to a lower speed to maintain print quality and avoid extrusion problems.
3. Optimize Extrusion Path: If you have a Bowden extruder, try using a filament guide or switch to a direct drive extruder if possible, as it significantly improves handling with flexible filaments.
4. Ensure Proper Storage: Like most TPU filaments, VarioShore is moisture-sensitive. Store it in a dry, sealed container when not in use to prevent moisture absorption, which can affect print quality.

Recommended Slicer Settings for VarioShore TPU

For most slicers like Ultimaker Cura, PrusaSlicer, or Simplify3D, you can start with the following basic settings and adjust according to your specific needs:

• Extruder Temperature: 200°C - 250°C
• Bed Temperature: 50°C - 60°C
• Print Speed: 20 - 40 mm/s
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