PEBA (Polyether Block Amide / TPA)
polymerthermoplastic elastomeric polyether block amide copolymer
PebaxPebax 2533Pebax 3533TPAHP 3D HR TPA 03HP MJF TPAThermoplastic Polyamide ElastomerTPE-A
Mechanical & thermal properties — 2 conditions
| Property | SLS as-built XY (Pebax 2533 / Shore A 35 grade) | MJF as-built (HP 3D HR TPA 03, XY) |
|---|---|---|
| Elastic modulus | 0–0 GPa | 0–0 GPa |
| Ultimate tensile strength | 20–30 MPa | 25–36 MPa |
| Elongation at break | 200.0–350.0 % | 160.0–250.0 % |
| Density | 0.98–1.04 g/cm³ | 1.00–1.06 g/cm³ |
Values shown as min–max where a spread is reported, otherwise as typical ± unit. Ranges reflect inter-source variation, not single-sample scatter. All values are for AM-processed specimens unless noted.
Engineering considerations
- Lattice structure design for energy return: PEBA's unique property in AM is the ability to print support-free 3D lattice structures with tunable compliance. Use triply periodic minimal surface (TPMS) lattices (gyroid, Schwartz P) or BCC/octet truss for midsole applications. Target 20–35% volume fraction for midsole energy return — verify with drop tower or instron cyclic compression testing. Hyperelastic FEA (Mooney-Rivlin model) is required for accurate simulation.
- Hardness grade selection: Pebax family spans Shore A 25 (Pebax 1074: very soft, high rebound) to Shore D 65 (Pebax 7233: near-rigid PA). For midsoles: Shore A 25–40 typical. For orthotics: Shore A 35–55 depending on patient weight and activity. For soft robotic grippers: Shore A 30–45. HP TPA 03 (Shore A 42) is a good general-purpose grade for MJF.
- Elastic recovery and hysteresis: PEBA achieves >90% elastic recovery at strains below 30%, dropping to ~75–80% at 50% strain. For energy-return applications, design the lattice geometry to keep maximum local strut strain below 20–25% at peak load. Measure energy return per ISO 17707 (footwear sole testing) for midsole applications — correlate to lattice simulations.
- Medical orthotic design: for custom orthotics, scan patient anatomy (structured light or CT), generate custom STL, print in PEBA. Key design parameters: wall thickness 1.5–3 mm for structural support, lattice fill for cushioning zones. Verify fit with 3D-scanned foot model before printing. Patient-specific AFOs with SLS PEBA outperform traditional thermoformed shells in comfort and compliance per clinical studies.
- Temperature performance: PEBA remains elastic from –40°C to +80°C (polyether soft segment Tg ~–50 to –60°C). At service temperatures above 80°C, PA hard segments approach their softening range — PEBA loses structural integrity above ~100°C. For applications above 60°C, verify material selection with DMA thermal scan.
- Powder management: PEBA powder is hygroscopic (polyether blocks absorb moisture). Store powder sealed with desiccant. Moisture affects flowability and sintering quality. Dry PEBA powder at 50°C for 4 h before use. Monitor powder MFR after each run — limit to 50% recycled powder for dimensional-critical applications.
- Joining and assembly: PEBA parts can be adhesively bonded with polyurethane adhesives (PEBA–PU bond) or cyanoacrylate (with surface activation). For midsole–outsole assembly: polyurethane adhesive is standard (same as conventional foam midsole bonding). Mechanical fasteners are less suitable — PEBA's high elongation allows fastener pull-through. Ultrasonic welding possible with optimised amplitude and hold settings.
Advantages
- Elastic energy return >90% at low strains (<30%) — highest of any common SLS/MJF elastomer. Enables true energy-return midsole performance vs foam (~55–70% return)
- Lowest density elastomer available in SLS/MJF (1.01 g/cm³) — lighter than TPU (1.22 g/cm³) and comparable to PA12 (0.93 g/cm³)
- Support-free powder bed process: internal lattice structures, undercuts, and complex flexible geometries printable without support removal marks
- Tunable hardness: PEBA family spans Shore A 25 to Shore D 65 — select grade for specific stiffness requirement
- Excellent cold-temperature flexibility: PEBA remains elastic to –40°C and below (polyether soft segments have very low Tg) — ideal for outdoor and cold-chain applications
- Good chemical resistance: polyether blocks resist water, alcohols, and mild solvents. PA hard blocks provide structural integrity
- Thermoplastic — fully recyclable (unlike crosslinked rubbers). Powder can be reused at standard refresh ratios
- Biocompatible grades available: Pebax is skin-contact biocompatible; suitable for medical orthotics and wearable devices
Limitations
- Only available in SLS and MJF — no FDM filament commercially available in standard PEBA grades. Cannot use on desktop FDM machines
- Narrow SLS sintering window: PEBA powder processing requires precise bed temperature control — more challenging than PA12. Bed temperature uniformity critical to avoid warpage or incomplete fusion
- Higher cost than PA12 powder: PEBA is typically 2–4× the powder cost per kg of PA12, plus higher machine time cost — not suitable for cost-driven prototyping
- Limited material availability: fewer qualified PEBA powder sources than PA12. Primary SLS PEBA: Arkema/ELF Atochem. MJF: HP TPA 03. No open-parameter SLS PEBA widely available for non-EOS machines
- Dimensional accuracy challenges: large elastic deformation makes dimensional measurement and tolerance specification non-trivial. Parts may deform during handling — design with appropriate handling fixtures
- Not compatible with standard PA12 powder: PA12 and PEBA powders cannot be mixed in the same SLS bed. Dedicated machine or thorough cleaning required when switching materials
- UV degradation: polyether blocks are susceptible to UV oxidation — outdoor PEBA parts require UV-stabilised surface coating for sustained outdoor use
- Limited post-processing: dyeing is possible but less uniform than PA12. Vapour smoothing has limited effect on PEBA due to different solubility vs PA12. Surface texture is as-built sintered particle Ra ~12–18 µm
Typical applications
Sports shoe midsoles: SLS/MJF lattice structures for custom energy-return footwear (Adidas Futurecraft, Nike AM concept)Medical orthotics: custom ankle-foot orthoses (AFO), insoles, prosthetic socket liners requiring conformable flexibilityProsthetic interfaces: PEBA liners between prosthetic socket and residual limb — comfort and impact absorptionFlexible connectors and bellows: chemical-resistant flexible joints in tube and hose assembliesVibration dampers and isolation mounts: SLS lattice structures tuned for specific frequency dampingSoft robotic grippers: compliant end-effectors for delicate assembly and pick-and-place operationsLattice energy-return structures: topology-optimised lattice midsoles, cushioning pads, and impact absorbersWearable device straps and body-contact components: skin-safe, flexible, lightweightMedical device seals and gaskets: autoclave-compatible with good chemical resistanceSports protective padding: custom-fit impact protection (helmets, body armour) using lattice PEBA
Industries
consumermedicalindustrial
Standards & certifications
ISO-52904established
Process quality assurance for SLS/MJF polymer parts — applicable to PEBA for medical orthotic and prosthetic liner production
medicalconsumer
PEBA for medical orthotics requires additional compliance with ISO 10993 biocompatibility (skin-contact devices). Pebax grades (Arkema) have documented biocompatibility for skin-contact applications. HP TPA 03: verify biocompatibility documentation with HP for specific device class. For Class II or higher medical devices, full ISO 10993 test program required beyond material compliance.
Compatible AM processes (2)
Other polymer materials
PA12 (Polyamide 12)semi-crystalline thermoplastic polyamidePA12-CF (Carbon Fibre PA12)carbon fibre reinforced polyamide-12 compositePA11 (Polyamide 11)semi-crystalline thermoplastic polyamide (bio-based)PEEK (Polyether Ether Ketone)semi-crystalline high-performance aromatic thermoplasticPEKK (Polyetherketoneketone)semi-crystalline high-performance aromatic thermoplastic (PAEK family)ULTEM 1010 (Polyetherimide PEI)amorphous high-performance thermoplastic (polyetherimide family)PLA (Polylactic Acid)semi-crystalline bio-derived thermoplastic polyesterPETG (Polyethylene Terephthalate Glycol)amorphous/semi-crystalline copolyester thermoplasticABS (Acrylonitrile Butadiene Styrene)amorphous engineering thermoplastic terpolymerTPU (Thermoplastic Polyurethane)elastomeric thermoplastic block copolymerPC (Polycarbonate)amorphous engineering thermoplastic polycarbonateASA (Acrylonitrile Styrene Acrylate)amorphous engineering thermoplastic terpolymerNylon PA6 / PA66 (Polyamide 66)semi-crystalline engineering thermoplastic polyamidePP (Polypropylene SLS/MJF)semi-crystalline thermoplastic polyolefin
Related calculators
PackingBuild-chamber utilisation, virgin powder consumption, refresh cost, and cost/part for SLS and MJF. EOS P396, HP MJF 5200/4200, Farsoon 403P presets.Build Time EstimatorPer-process build time from part volume, layer count, and machine throughput. LPBF, SLS, FDM, SLA, DED, binder presets included.Cost-Per-Part EstimatorMachine hourly + material + labor + post-processing → unit cost with margin. Currency-agnostic.FDM Infill Weight & CostPattern × density × material cost. Quick feasibility for FFF prints.LatticeBCC, octet-truss, gyroid, Schwartz-P relative density and Gibson-Ashby stiffness/strength scaling. SA/V ratio for heat exchangers and scaffolds.
Last reviewed: 2026-05-15 · v1 · Sources: verbelen-2017-peba-sls, chen-2019-tpa-sls, chung-2020-peba
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