3D Printing for Wearable Technology:
How Photopolymers Change the Manufacturing Landscape

Wearable technologies, often referred to simply as wearables, are electronic devices or accessories that can be worn on the body.

In most cases, these technologies establish connections between specific smart products, like smartwatches and smartphone applications. This allows users to access the intelligent features of these products from anywhere, as long as they have an active internet connection.

3D printed wearable devices are designed to perform various functions, ranging from tracking health and fitness metrics to providing convenient access to information or communication. They have gained popularity in recent years due to advancements in technology and their potential to enhance daily life in a variety of ways.

Additionally, users have the ability to manage different functions of these wearable devices through their corresponding mobile applications. Common examples of wearable technologies include smartwatches, fitness trackers, smart clothing and health monitors.

Enclosures and Housings

Photopolymers create finely detailed and precise structures, ensuring that the enclosures fit perfectly around the internal components of the wearable device. The smooth finish achieved with photopolymers contributes to the comfort and aesthetics of the products, as rough edges or surfaces can be prevented.

Buttons and Controls

Photopolymer-based 3D printers can work with multiple materials simultaneously. This allows for the creation of buttons with different properties, such as varying levels of tactility or feedback. Certain photopolymers can be transparent, making them suitable for creating clear or translucent buttons. This can be useful for wearables with displays or backlit controls.

Straps and Bands

Photopolymers can be engineered to possess a high degree of flexibility while maintaining durability, ensuring that straps and bands remain comfortable even during movement. Many photopolymers are biocompatible, meaning they are safe for direct skin contact. This is crucial for 3D printed wearable devices, as users wear them for extended periods.

Optical Components

Optical components are used for display screens, lenses, and sensors, which require precision and clarity. Besides transparency, photopolymers can be engineered to incorporate anti-reflective coatings, improving optical performance by reducing glare and reflections.

Skin-Friendly Properties

Photopolymers used in wearables must be biocompatible, which means they should not cause irritation, allergies or any adverse reactions when worn for extended periods. This requirement is essential in creating wearables that prioritise user comfort and safety, making them suitable for long-term use without compromising skin health or well-being.

Chemical Resistance

Photopolymers must exhibit chemical resistance, which means that they should be able to withstand exposure to various substances, such as lotions, detergents and other chemicals commonly encountered in daily life. This property ensures that the material remains stable and does not degrade or react negatively when in contact with different compounds. By possessing good chemical resistance, photopolymers contribute to the overall durability and reliability of 3D printed wearables.

Flexibility and Durability

Photopolymers must possess both flexibility and durability. These properties are crucial for creating components like straps, bands and enclosures that need to withstand movement and wear without becoming brittle or deformed. Flexibility ensures that wearables can conform comfortably to the contours of the body, providing a snug fit for the user. At the same time, durability ensures that these components remain intact and functional even under regular use and potential stress. Striking the right balance between flexibility and durability is essential in crafting wearables that are both comfortable and long-lasting.

Water and Moisture Resistance

3D printed wearable devices should be capable of withstanding exposure to water, sweat and other forms of moisture without degrading or experiencing structural damage. This property is crucial for wearables, as they are often worn in various environments and may come into contact with liquids. Also, consumers are used to employing wearable technology during sports, so that water and moisture resistance is imperative for a wide range of wearables.

Compatibility with Electronics

Photopolymers must be compatible with electronic components to allow the devices to function effectively. This means that the material should not interfere with the functionality of sensors, circuits or other electronic elements integrated into the wearable device. Additionally, it should not cause electromagnetic interference or hinder signal transmission.