Carbon introduces EPU Pro Platform for single part, dual cure elastomers

Carbon’s EPU Pro Platform is the next generation of elastomeric resins for additive manufacturing. This single-part, dual-cure family of elastomers is designed to offer high performance and better usability, enabling more end-use applications. With the launch of EPU Pro, Carbon introduces an even wider range of mechanical responses for latticed products and end-use parts.

EPU Pro can deliver a wide range of stiffness options, with durometers ranging from 50A to 90A. This flexibility allows manufacturers to fine-tune material properties to suit specific application needs. The addition of foaming agents further enhances this range, enabling the production of parts with a distinct aesthetic and tactile appeal. These foaming agents create unique textures and finishes, which are particularly valuable for industries such as footwear and consumer products where appearance and feel play a crucial role.

The platform is also engineered for ease of use. Unlike traditional dual-cure materials, which require precise mixing and careful handling, EPU Pro is a single-part system. This innovation simplifies the manufacturing process but also reduces material waste, making it an efficient choice for both prototyping and large-scale production. Additionally, the extended pot life of EPU Pro ensures that unused resin can be easily reused, further contributing to its sustainability.

Another key advantage of EPU Pro is its sustainability. Carbon has designed the platform with eco-friendly practices in mind, including solvent-free cleaning processes and the ability to reprocess cured parts through melt-processing. These features align with the growing demand for sustainable manufacturing solutions, making EPU Pro an attractive option for companies looking to reduce their environmental footprint.

The science behind dual-cure elastomers

Dual-cure technology is a cornerstone of Carbon’s material innovation. This process involves two distinct curing stages: an initial photopolymerization step followed by a thermal cure. This dual-cure mechanism allows for precise control over the material’s mechanical properties, ensuring consistency and reliability across a wide range of applications.

Traditional dual-cure materials often rely on two-part systems, requiring careful mixing to achieve the desired results. However, EPU Pro’s single-part formulation eliminates this step, streamlining the manufacturing process. This advancement not only saves time but also reduces the need for specialized equipment, making the technology accessible to a broader range of manufacturers.

EPU Pro’s enhanced printability opens the door to new design possibilities that were previously unattainable with traditional elastomers. The material’s high strength across the durometer range allows for the creation of both intricate geometries and large, robust structures. This capability is particularly beneficial for industries that require complex lattice designs, such as seating solutions and footwear.

The novel haptics offered by EPU Pro resins further set them apart from other materials in Carbon’s portfolio. These resins can be tuned to achieve a variety of tactile qualities, from a silky smooth finish to a suede-like texture. This level of customization enables manufacturers to create products that not only perform well but also provide a unique user experience. The combination of aesthetic appeal and functional performance makes EPU Pro an ideal choice for consumer-facing products.

Application areas of EPU Pro

EPU Pro’s versatility makes it suitable for a wide range of applications across various industries. In the footwear sector, the material enables lightweight designs that offer exceptional performance and comfort. The ability to create complex geometries and finishes allows designers to push the boundaries of traditional footwear aesthetics, resulting in products that are both visually striking and functionally superior.

EPU Pro materials can also provide a unique balance of cushioning and support to performance seating. The material’s adaptability allows for the creation of seating solutions with varying stiffness levels, catering to diverse user needs. Additionally, the higher print strength of EPU Pro enables the production of larger parts and curved surfaces, which are essential for ergonomic designs.

For grips and handles, EPU Pro’s unique haptics and customizable stiffness make it an ideal choice. The material allows for the creation of soft structures with exceptional hand feel, enhancing user comfort and control. The ability to incorporate breathability into lattice designs further adds to the functionality of these products, making them suitable for high-performance applications.

Carbon’s existing elastomer portfolio includes products like EPU 45 and EPU 46, each designed for specific performance characteristics. EPU 45 is known for its energy-damping properties, while EPU 46 offers high energy return and is derived from bio-based sources. EPU Pro builds on these foundations by expanding the range of mechanical responses available. Its single-part formulation and enhanced printability make it a more versatile option for manufacturers seeking a balance between usability and performance.