Tag Archives: silicone

Finally, You Can 3D-Print Real Silicone Molds and Gaskets on Your Prusa 3D Printer

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Anyone who’s worked with flexible 3D printing filaments knows their limitations; TPU and TPE only go so far, and nothing on the desktop market has matched the heat resistance and elasticity of real silicone. We’ve been stuck making parts that feel rubbery but fail the moment they get too warm or need to seal properly. That’s all changed with the arrival of Prusa’s new XL printhead, developed in collaboration with Filament2. This toolhead uses a pioneering dual-filament system to produce actual, industrial-grade silicone prints, a feat that moves desktop printing into a whole new category of material science.

Instead of extruding a simple thermoplastic, this system feeds two liquid-core filaments into the nozzle, where their outer sheaths are stripped away. The liquid silicone components are then mixed and cured in real time as they are deposited. This is not some rubber-like substitute; it is genuine silicone with all its useful properties, created right on the print bed of a standard Prusa XL. The elegance of containing the entire two-part mixing process within a clean, self-contained filament and toolhead system is a massive engineering win, solving the mess and complexity that has kept liquid printing out of reach for most people until now.

Designer: Prusa

This method completely sidesteps the need for the clumsy pumps and reservoirs seen in previous experimental liquid printers. The genius is in the filament itself. By encasing the two liquid parts in a stable sheath, Filament2 has created something that handles just like a standard spool of PLA. The printhead does the heavy lifting, performing a micro-scale version of what you would do with a two-part epoxy, but with incredible precision. You get the benefits of a reactive polymer without the hazardous mess, which opens up a world of possibilities for creating functional, end-use parts, not just look-alike prototypes.

Think about the immediate applications for this technology. In the automotive world, the ability to print custom, one-off silicone gaskets, seals, and vibration dampeners is a game changer for restoration and prototyping. No more waiting weeks for a custom mold or settling for a close-enough part. For product designers, this means creating truly functional prototypes with soft-touch grips, flexible waterproof seals, and even custom ergonomic components for wearables. Because silicone is skin-safe and can be sterilized, it also opens up possibilities for custom medical models and assistive devices. We are talking about end-use parts, not just look-alike models.

The choice to launch this on the Prusa XL platform is also incredibly clever. The XL’s main selling point is its automatic tool-changing capability, which suddenly makes it the perfect machine for true multi-material fabrication. You could print a rigid nylon housing with one toolhead, then have the printer automatically swap to the silicone head to print integrated waterproof seals and vibration-dampening feet onto the same part in a single, uninterrupted job. This elevates the machine from a multi-color printer to a genuine multi-property manufacturing station. It’s a level of automation and material integration that was previously reserved for machines costing tens of thousands of dollars.

Now, it’s important to keep expectations grounded. This will not be as simple or cheap as printing with standard PLA. The specialized filament from Filament2 will undoubtedly carry a premium price, and I anticipate a learning curve. The process requires incredible precision; any imbalance in the mixing ratio or inconsistency in the liquid cores could lead to failed prints where the silicone doesn’t cure properly. We still need to see long-term reliability data and learn about the maintenance requirements for a printhead that handles what are essentially reactive adhesives. Still, even as a niche application, it pushes the entire industry forward by showing what’s possible when you rethink the entire printing process, from the filament spool to the nozzle tip.

The post Finally, You Can 3D-Print Real Silicone Molds and Gaskets on Your Prusa 3D Printer first appeared on Yanko Design.

Headphones concept reimagines comfort with clear silicone headbands

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Even with the popularity and ubiquity of wireless earbuds, many audiophiles and gamers still have a soft spot for over-ear headphones. Despite their bulkiness, they still promise better noise isolation and fuller sounds, which is to be expected given their size. They are also expected to be less comfortable to wear over longer periods of time, despite many attempts at using different materials and even designs. This concept design for an aptly named “Comfortably Headphones” takes another stab at that problem, but its solution is more ambitious and, if we’re being honest, less practical. Then again, having a flexible and transparent silicone band is sure to get you some attention, at least during the time you’re comfortably wearing them.

Designers: Belrtarducci, Garabatfire (MinimalChat Studio)

Headphone headbands have always been solid and rigid for a reason. They need to provide sufficient structure and support to hold the large and heavy ear cups together while also ensuring the whole device sits securely on your head. That said, that same rigidity is one of the biggest sources of discomfort for users, and many designers have tried to alleviate the issue with comfortable fabrics or soft materials wrapped around the band or, better yet, make the band slightly more bendable to accommodate different head shapes.

This design concept, however, throws tradition out the window completely by replacing the usual metal bands with nothing but silicone, a material known for its flexibility and plasticity. Silicone can retain the shape it was formed into during production, but it can also slightly bend and even twist with enough force. It won’t perfectly conform to everyone’s head shapes, but it will at least put less pressure on your head while you’re wearing it, at least in theory.

It isn’t just regular silicone that was chosen for this design either; it is a transparent variety. This creates reflections and refractions that add a unique visual flavor to the headphones. At least under some light, it creates more playful and more natural rainbow colors better than what any RGB LED lighting can provide. Of course, it doesn’t do much in the dark, but even the organic form of shadows can become a source of fascination.

Sadly, such a mesmerizing design does have its share of flaws, particularly with the longevity of silicone as a material. It can warp and deform over time, and discoloration is a common phenomenon with “clear” silicone products. Then there’s also the fact that wires bridging the two halves of the headphones mars the transparent beauty of the silicone band unless the headphones are completely wireless even internally. At that point, however, the benefits of such large audio equipment become moot, and people might as well switch to lighter earbuds. Of course, you could just create a solid, opaque silicone band, but then where would be the fun in such a design?

The post Headphones concept reimagines comfort with clear silicone headbands first appeared on Yanko Design.