Hi all, I’m hitting a brick wall and could really use some help. I’m working on a project that requires a large piece of semi flexible material ( ~Shore60 TPE Molded ( my best guess)) Its a piece that fits over the vents on heaters found in motels. This piece needs to be flexible enough to conform to the varying motel profiles that are in use. Its too large for SLS prints, too soft for machining, any other thoughts? Any feedback is valuable.
Call around to prototype shops in your area and ask if they run an Objet Connex Machine. It has a 19.7 × 15.7 × 7.9 in. build volume and capable of printing a rubber like material in 60 shore.
Machine ABS and get the final finish you are looking for on the surface, then cast a silicone mold, then pour the urethane. You will be able to get a short “production” run of prototype parts and test different durometers.