3D-Printed Protective Button Covers for Technical Devices

Abstract:

Protective foils for buttons fabricated using 3D printing with TPU (Thermoplastic Polyurethane) material offer innovative solutions for enhancing durability, functionality, and user experience in various applications. TPU, known for its elasticity, abrasion resistance, and transparency, is ideal for creating thin, flexible foils that shield buttons from wear, moisture, and contaminants while maintaining tactile feedback. The 3D printing process allows for precise customization, enabling the production of foils that fit specific button designs with high accuracy. This approach is particularly beneficial in sectors like consumer electronics, automotive, and industrial equipment, where buttons are subject to frequent use and harsh conditions. Moreover, TPU's resilience ensures long-lasting protection without compromising the aesthetic or ergonomic qualities of the buttons. The integration of 3D printing technology facilitates rapid prototyping and production, allowing for quick iterations and tailored solutions to meet diverse protective needs. Overall, the use of TPU in 3D-printed protective foils represents a significant advancement in the design and manufacture of durable, high-performance button covers.

• Periodical: Key Engineering Materials (Volume 1031)
• Pages: 55-64
• DOI: https://doi.org/10.4028/p-0tic7J
• Online since: November 2025
• Authors: Cristian State*, Denis Andrei Predu
• Keywords: 3D Printing Accuracy, Design Optimization, Fusion Deposition Modeling, Layer-by-Layer Fabrication, Material Properties, SLA 3D Printing

References

[1] 3D LifePrints UK Ltd (2020). Medical 3D Printing at the Point of Care - Improving Patient Outcomes With 3D Technologies.

[2] Parikh, H.H., Jadav, R., Joshi, P. (2023). 3-D Printing: A Review of Manufacturing Methods, Materials, Scope and Challenges, and Applications.

[3] Vallejo, D.O., Aroca, I., Lara, P., Paguay, A. (2024). Mechanical Testing and Durability Evaluation of 3D Printed Magnetic Closures for Adaptive Fashion.

DOI: 10.1007/978-3-031-63437-6_1

[4] https: //www.wevolver.com/article/how-3d-printing-is-enabling-faster-design-higher-productivity-and-more-customization-in-manufacturing.

[5] https://oxmaint.com/blog/post/5-causes-of-equipment-failure.

[6] Aramide, B.P., Popoola, A.P.I., Sadiku, E.R., Aramide, F.O., Jamiru, T., Pityana, S.L. (2021). Wear-resistant metals and Composites.

DOI: 10.1007/978-3-030-36268-3_177

[7] https://limblecmms.com/blog/equipment-failure/.

[8] Matos, M.A., Rocha, A.M.A.C. & Costa, L.A. Many-objective optimization of build part orientation in additive manufacturing.

[9] Bertling, J., Rommel, S. (2016). A Critical View of 3D Printing Regarding Industrial Mass Customization Versus Individual Desktop Fabrication. In: Ferdinand, JP., Petschow, U., Dickel, S. (eds) The Decentralized and Networked Future of Value Creation.

DOI: 10.1007/978-3-319-31686-4_5

[10] Chadha, U., Abrol, A., Vora, N.P. et al. Performance evaluation of 3D printing technologies: a review, recent advances, current challenges, and future directions.

DOI: 10.1007/s40964-021-00257-4

[11] Arefin, A. M. E., Khatri, N. R., Kulkarni, N., & Egan, P. F. (2021). Polymer 3D Printing Review: Materials, Process, and Design Strategies for Medical Applications.

DOI: 10.3390/polym13091499

[12] Iftekar, S.F.; Aabid, A.; Amir, A.; Baig, M. Advancements and Limitations in 3D Printing Materials and Technologies: A Critical Review. Polymers 2023.

DOI: 10.3390/polym15112519

[13] Cook, R. D., Malkus, D. S., Plesha, M. E., & Witt, R. J. (2002). Concepts and Applications of Finite Element Analysis.

[14] Manero, A.; Sparkman, J.; Dombrowski, M.; Smith, P.; Senthil, P.; Smith, S.; Rivera, V.; Chi, A. Evolving 3D-Printing Strategies for Structural and Cosmetic Components in Upper Limb Prosthesis.

DOI: 10.3390/prosthesis5010013

[15] Kristiawan, R. B., Imaduddin, F., Ariawan, D., Ubaidillah, & Arifin, Z. (2021). A review of the fused deposition modeling (FDM) 3D printing: Filament processing, materials, and printing parameters.

DOI: 10.1515/eng-2021-0063

[16] https://omnexus.specialchem.com/selection-guide/thermoplastic-polyurethanes-tpu.

[17] Xu, T., Shen, W., Lin, X., & Xie, Y. M. (2020). Mechanical Properties of Additively Manufactured Thermoplastic Polyurethane (TPU) Material Affected by Various Processing Parameters.

DOI: 10.3390/polym12123010

[18] https://www.creality.com/products/ender-5-pro-3d-printer.

[19] Naba Kumar Kalita, Minna Hakkarainen, Integrating biodegradable polyesters in a circular economy, Current Opinion in Green and Sustainable Chemistry Volume 40, 2023, 100751, ISSN 2452-2236.

DOI: 10.1016/j.cogsc.2022.100751

[20] Nishida, H. (2011). Development of materials and technologies for control of polymer recycling.

[21] https://www.matweb.com/.

[22] https://3dsolved.com/best-filament-to-3d-print-phone-cases/.

[23] https://www.mufasaspecialties.biz/jual-thermoplastic-polyurethane/.

[24] https://patents.google.com/patent/EP2271712B1/en.

[25] https://reliancerubberindustries.com/materials/silicone/?utm_source.

[26] https://www.angreen.com/news/density-of-thermoplastic-polyurethane-in-different-applications-in-cable.html?utm_source.

[27] https://www.rubber-tools.com/silicone-rubber-density-lb-in3-guide-in-depth/?utm_source.