3D Systems' DuraForm Flex plastic SLS material is being used by Reebok to produce flexible yet tough prototype footwear, sandals and athletic equipment.
3D Systems Corporation reports that Reebok is successfully utilising the company's DuraForm Flex plastic for a number of its products, which illustrates the remarkable properties of this flexible, soft, yet tear-resistant and durable material. This thermoplastic elastomer is suitable for creating complex, functional prototype footwear, sandals and athletic equipment - as well as industrial products such as prototype gaskets, hoses, seals and miscellaneous plastic parts.
Reebok has found DuraForm Flex plastic to be easy to process in its 3D Systems Selective Laser Sintering (SLS) system. Unlike earlier generation materials, DuraForm Flex directly produces durable parts. Secondary infiltration is optional, so users can add colour, improve burst strength and create a water-tight barrier. Five colours are available – black, red, yellow, blue and natural - which can be mixed to create custom colours.
3D Systems says Reebok produces parts at a 0.15mm layer thickness, which is comparable to other flexible materials, yet DuraForm Flex plastic delivers an exceptional surface finish and the ability to create parts with fine-feature details. By further reducing layer thicknesses from 0.15mm to 0.1mm, DuraForm Flex plastic offers up to a 33 per cent improvement in resolution. Parts built from DuraForm Flex plastic can to withstand repeated bending and flexing, as well as harsh functional testing. By varying machine process conditions, this material can consistently create parts with optimised Shore A hardnesses ranging between 45 and 75.
Gary Rabinovitz, Rapid Prototyping Lab Manager at Reebok, comments: "Our application is different than most. We build one or two confirmation samples out of 3D Systems' DuraForm Flex plastic. The parts are very flexible and can be painted, so we get the look and feel of a real shoe. For this type of application, we prefer DuraForm Flex to all the other materials available on the market."
Paul Bates, Director of Advanced Process Engineering for Reebok International, adds: "Duraform Flex material gives us a much more consistent and stable material for our flexible parts. We can setup large complex builds that run overnight with the confidence that we will have good results in the morning."
Abe Reichental, 3D Systems' President and Chief Executive Officer, states: "3D Systems developed DuraForm Flex plastic based on customer suggestions for an improved elastomeric material. We listened to their ideas and integrated the desired properties into this next-generation flexible material. The synergy between this material and our SLS systems enables our customers like Reebok to produce usable parts quickly, shortens product development time, reduces time-to-market and simplifies customisation without incurring any capital tooling expense."
