SLS 3D Printing with TPU Powder for Honeycomb Pillows: Flexible, Breathable, and Customizable

Pillows are one of those everyday objects that most people never think about—until they experience poor sleep or neck pain. Traditional pillows rely on foam, down, or fiberfill, each with trade-offs: heat retention, limited breathability, and a one-size-fits-most approach that leaves many users uncomfortable.

Selective Laser Sintering (SLS) with TPU powder is changing that. This flexible elastomer material enables the production of honeycomb-structured pillows that are breathable, supportive, and customizable—without the tooling costs of traditional foam molding.

This article explores how SLS 3D printing with TPU is being applied to pillow manufacturing, from travel pillows to medical cushions, and what makes honeycomb lattice structures ideal for comfort applications.

Why SLS with TPU for Pillows?

TPU (Thermoplastic Polyurethane) is an elastomer known for its flexibility, durability, and skin-safe properties. When combined with SLS 3D printing, it unlocks design possibilities that traditional foam cannot match.

True Flexibility in Powder Form

Formlabs introduced TPU 90A Powder as the first flexible material for its Fuse series SLS printers. The material offers high tear resistance and elongation at break of 110–310%, making it suitable for durable, functional parts that flex and recover . Unlike rigid nylons used in most SLS applications, TPU 90A delivers the softness and bounce required for cushioning.

The material is also skin-safe, making it ideal for applications that contact the human body—including prosthetics, orthotics, and wearables.

Low Refresh Rate, Lower Cost

TPU 90A Powder has the lowest refresh rate (20%) among Formlabs SLS materials, reducing waste and lowering per-part cost for small-batch production . This makes SLS with TPU economically viable for custom pillows and low-volume production runs.

Support-Free Lattice Structures

SLS requires no support structures—the powder bed naturally supports the part during printing. This enables complex honeycomb and lattice geometries that would be impossible with FDM or injection molding . For pillows, this means internal structures can be optimized for breathability, support, and weight reduction.

Honeycomb Lattice Structures for Pillow Comfort

The honeycomb or lattice structure is what makes SLS-printed TPU pillows different from traditional foam.

Breathability and Temperature Regulation

Traditional foam traps heat. A honeycomb lattice creates an open matrix that allows air to flow from all sides, keeping the pillow cool . Travel Blue’s Airflow 3D-printed pillow—launched in 2026—uses exactly this principle: a TPU lattice structure designed to flex under pressure while allowing continuous airflow.

Ergonomic Support Without Pressure Points

A well-designed lattice distributes pressure evenly, reducing pressure points on the neck and head. The structure can be tuned—by adjusting cell size, wall thickness, or strut diameter—to provide different levels of firmness for different applications.

Lightweight and Portable

Lattice structures remove unnecessary material, creating pillows that are significantly lighter than foam equivalents. Travel Blue’s Airflow pillow is described as “slim and very light,” making it ideal for travel.

Washable and Hygienic

Unlike foam, which absorbs moisture and can harbor bacteria, a TPU lattice can be cleaned and sanitized instantly . This is particularly valuable for travel pillows, medical cushions, and shared-use applications.

Real-World Applications

Travel Blue Airflow Travel Pillow

Travel Blue launched the Airflow in September 2026, calling it the first 3D-printed travel pillow in travel retail. The pillow uses a TPU lattice structure designed to prevent the head from dropping sideways or forward while providing ergonomic support. Its open matrix construction keeps it cool, and it retails for €69.90 .

The production process—SLS 3D printing with TPU—will be demonstrated live at the TFWA World Exhibition in Cannes, with a working 3D printer on the stand.

Custom Rehabilitation Headrests

TPM3D produces custom rehabilitation headrests using TPU powder and SLS printing. These headrests are designed from patient medical imaging and 3D scan data to provide personalized cervical support. After printing, they undergo chemical vapor smoothing to improve toughness and surface finish, achieving the durability needed to support the weight of the head and neck.

Automotive Seat Cushions

A 2026 study published in the journal Virtual and Physical Prototyping investigated SLS-fabricated TPU lattice structures for automotive seating. The research used a Kelvin lattice geometry and evaluated cushion properties including sag factor (support feel) and hysteresis loss rate (energy dissipation). A full-scale automotive seat prototype was fabricated to demonstrate manufacturing feasibility.

The study found that laser power and hatch distance were the dominant factors affecting cushion performance, while scan speed had negligible influence. Life cycle assessment revealed that SLS offers environmental advantages at low production volumes. 

Custom Insoles and Orthotics

TPU powder SLS is also used for custom insoles and orthotics. TPM3D produces custom shoe insoles using TPU powder with vapor smoothing, achieving the flexibility and support required for foot comfort . The same principles apply to pillow design: customizable comfort based on individual anatomy.

Design Considerations for SLS TPU Pillows

Lattice Geometry Selection

Different lattice topologies offer different comfort characteristics:

Kelvin cells: Excellent energy absorption and uniform cell morphology 

Body-centered cubic (BCC): Bending-dominated behavior, compliant force-displacement 

Honeycomb: High strength-to-weight ratio with open airflow

For pillows, bending-dominated structures that compress smoothly under load are generally preferred.

Wall Thickness and Firmness

TPU 90A can be tuned for different firmness levels by adjusting wall thickness. Formlabs notes that “by modifying the design of the part, such as changing wall thickness, you can produce parts with different levels of hardness for different applications”.

Post-Processing for Comfort

As-printed TPU parts have a slightly tacky surface. For consumer-facing pillows, post-processing improves comfort:

Chemical vapor smoothing: Creates a smooth, durable surface and improves waterproofing 

Media blasting: Removes loose powder and creates a uniform matte finish

Powder Handling for TPU

TPU 90A Powder requires special handling. It tends to settle over days and requires stirring before printing to restore flowability. Formlabs recommends sifting at 35–40°C (warm but not unsafe to handle) to prevent powder caking on parts . These considerations are important for manufacturers planning production runs.

The SLS2030 for TPU Pillow Production

The Supermaker SLS2030 is an industrial SLS printer well-suited for TPU pillow manufacturing.

Why the SLS2030 Excels for TPU Pillows

Large Build Volume: The 200 × 200 ×300 mm build capacity accommodates multiple pillows or pillow components per build, reducing per-part cost and enabling production-scale throughput.

Support-Free Lattice Printing: Honeycomb and lattice structures print without support removal, preserving delicate internal geometries.

Material Versatility: The SLS2030 supports TPU and other engineering powders, enabling both flexible cushioning layers and rigid structural components.

Production-Ready Output: Parts from the SLS2030 can serve as end-use consumer products, not just prototypes.

Frequently Asked Questions

What is TPU 90A Powder?

TPU 90A Powder is a flexible elastomer material for SLS 3D printing, offering high tear resistance, 110–310% elongation at break, and skin-safe properties.

Can SLS print honeycomb structures with TPU?

Yes. SLS’s support-free process enables complex honeycomb and lattice geometries that flex and recover under pressure.

Are SLS TPU pillows breathable?

Yes. The open lattice matrix allows air to flow from all sides, keeping the pillow cool.

Can SLS TPU pillows be customized?

Yes. The lattice structure, wall thickness, and overall geometry can be modified to adjust firmness and fit for individual users.

What post-processing is needed for TPU pillows?

Chemical vapor smoothing improves surface finish and waterproofing. Media blasting removes loose powder.

Conclusion

SLS 3D printing with TPU powder is enabling a new generation of pillows that are breathable, supportive, washable, and customizable. From Travel Blue’s Airflow travel pillow to custom rehabilitation headrests, the technology is proving itself in real-world applications.

The Supermaker SLS2030 offers the precision, build volume, and material versatility required for TPU pillow production. With its 200 × 200 × 300 mm build capacity,50W fiber laser, and support for flexible TPU materials, it can handle both prototyping and small-batch production runs.