Forward AM and OECHSLER develop new backpack padding with lattice structure for a comfortable journey

Challenge: Sweat-Free Hiking by Improving Backpack Design

The importance of comfortable outdoor sports gear for hikers cannot be overstated, and the point of contact between the body and the pack indirectly determines the comfort of the pack – if there is constant friction, heat is generated, then sweat, constant humidity , soreness and unpleasant odor.

Germany’s leading specialist in AM polymer processing
OECHSLER
took on the challenge of developing a new generation of backpacks designed to enhance the hiker’s experience. They thought about the function of the knapsack from scratch and asked two questions:

1. From the perspective of maximizing the comfort of the wearer, how to achieve the perfect hip web design?

2. How can an already “ergonomic” back pad be improved?

The Solution: Lattice Structures 3D Printed Using Advanced Ultrasint® TPU01

Yuk
Xerox
use3D printingThe lattice structure replaces the foam traditionally used in backpack waistbands and back pads. This structure features a fully integrated cushioning system for great comfort: the smart lattice geometry allows for flexible adjustment of its cushioning performance by precisely calibrating changes in strut thickness and overall dimensions of the lattice elements.
At the same time, this highly innovative lattice design significantly reduces the maximum and average contact pressure with the human body; the 3D-printed dorsal pad and the open-pore structure of the anal fin maximize ventilation and reduce heat build-up, thereby significantly reducing the Temperature and humidity build-up at the point of body contact.
Therefore, the OECHSLER team was able to maximize the cushioning properties of the back pad and the comfort of the wearer by designing specific regions of the lattice structure and providing varying degrees of elasticity and stiffness.

Forward AM’s Ultrasint® TPU01 is the perfect material for elastic lattice designs. This high-performance polymer powder makes 3D printing lattice structures simple, fast and extremely cost-effective:

1. The material has excellent abrasion resistance, which solves the challenges posed by the constant friction of 3D printed parts against the wearer’s body – Ultrasint® TPU01 enables durable performance of parts.

2. The combination of the lattice structure and Ultrasint® TPU01 results in a lightweight part – very important for outdoor athletes.

3. Advanced Ultrasint® TPU01 has successfully passed strict ISO 10993-10 and ISO 10993-5
standard
Skin sensitization and cytotoxicity tested for complete confidence in human contact applications.

4. Ultrasint® TPU01 has excellent UV and hydrolysis resistance – so it is very suitable for outdoor sports.

5. As a thermoplastic, Ultrasint® TPU01 can be easily recycled at the end of the product’s useful life – complying with Forward AM’s circular economy principles and meeting the sustainability requirements of modern outdoor gear.

For manufacturers, the dorsal pad and anal fin can be produced as a single lattice element – ​​which means a huge reduction in assembly steps, time and cost, as no gluing or stitching is required.

The result: new backpack padding with improved comfort, sustainability and cost-effectiveness

Combined with a 3D printed lattice design, OECHSLER’s backpack padding printed with BASF Forward AM’s advanced Ultrasint® TPU01 material offers hikers a whole new experience with a wide range of benefits:

1. Maximize air circulation

2. Significantly reduces temperature and relative humidity build-up in the back contact area of ​​hikers

3. Reduce the maximum contact pressure and average contact pressure

4. Adjustment of shock absorption characteristics by different hardnesses in the individual print elements

5. Unlimited design flexibility

6. Simple and fast assembly, which greatly reduces cost and time

7. 3D printingMaterials are 100% recyclable

(responsible editor: admin)