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Farsoon Technologies & Wanhua Chemical Group: Innovative 3D-Printed TPU Helmet for 2022 Winter Olympic Bobsled Team

By Farsoon Technologies

Industry: Commercial Technology: Dual-laser Flight® Technology Material: WF-PU95AB TPU Machine: Flight 403P-2 dual laser

Farsoon Technologies & Wanhua Chemical Group: Innovative 3D-Printed TPU Helmet for 2022 Winter Olympic Bobsled Team

Precision Protection for Olympic Glory: 3D Printed Helmet for the Bobsled Champions of Tomorrow.



Farsoon, the leading supplier of industrial AM technology in China with a growing presence in the global market, collaborated with Wanhua Chemical, a renowned producer of MDI, TDI, and polyol, to innovate a 3D Printed TPU Helmet for the 2022 Winter Olympic Bobsled Team. The bobsled helmet lining was fabricated using Wanhua Chemical's specialized TPU material, tailored for exceptional performance in extreme temperatures, and Farsoon's advanced dual-laser Flight® Technology. In addition, Farsoon’s Flight® Technology, employing powerful fiber lasers instead of standard CO2 lasers, offers enhanced power delivery to the powder bed and increased longevity, crucial for ROI in manufacturing applications. Furthermore, the latest iteration of Farsoon’s dual fiber laser Flight® Technology enables industrial-scale production turnover with TPU material. With two 300-watt Fiber lasers and dynamic optical systems, it produces two ultra-fine laser spots at a rapid scanning speed of up to 20m/s (66ft/s) each. The Flight 403P’s expanded cylinder size allows for the production of two bobsled helmet linings in a single 7.5-hour build. Thanks to Farsoon’s open parameter strategy, Assoc. Prof. Li collaborated closely with Wanhua and Farsoon application teams to experiment with various parameter combinations, optimizing laser power, scan spacing, and layer thickness for the helmet lining lattice structure, balancing mechanical performance and weight requirements. The lattice structure, meticulously developed by the bobsled helmet R&D team, consists of multiple layers and buffer zones with varying hardness levels. Impact zones, designed to absorb damage from head collisions, feature structural distribution of different densities, providing athletes with unparalleled protection performance. The 3D-printed lattice lining, complemented by the carbon fiber shell, weighs only 1.1 kg, achieving a remarkable 500-gram reduction compared to traditional foam helmets.



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