TPU flexible enclosures for wearable electronics, settings that work

Cases, brackets, parametric designs. Mounting electronics in printed enclosures.
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danny_3dprint
Posts: 12
Joined: Tue May 05, 2026 11:00 am

Designed wrist-mounted ESP32 case, TPU 95A filament. Print fails 3 ways before getting clean parts.

Bad runs:
  • Filament jam at extruder (too soft for stock Bowden tube guide)
  • Stringing across overhangs (retraction defaults wrong for TPU)
  • Layer separation at bend zones (cooling fan too aggressive)
Settings that finally worked:
  • Print speed 25mm/s (slow, deliberate)
  • Retraction 1mm at 25mm/s (vs 6mm 45mm/s for PLA)
  • Cooling fan 30% (vs 100% PLA)
  • Nozzle 230C, bed 50C
  • Direct drive extruder strongly recommended (Bambu A1 Mini OK with patience)
Result: flexible case that survives 6+ months of wrist movement. PHP 280 per print.

Other TPU users here? Tips for thinner walls (mine settled at 2.5mm minimum)?
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