Mosaic Aero is a custom flexible foaming TPU engineered for adaptable performance across applications. Its low density and high elongation make it ideal for orthotics, prosthetics, custom packaging, footwear, and robotics components requiring cushioning, flexibility, and lightweight strength.
What is Aero?
Durable and easy to use. Explore Aero’s material specifications and key properties below.
Mechanical Properties
Aero’s mechanical behaviour is process-tunable, offering a broad performance range. With 300–490% elongation at break and a density of 1.22 g/cc, it delivers lightweight, high-stretch performance.
Thermal Properties
Mosaic Aero behaves similarly to flexible TPU materials in normal operating temperature ranges. It maintains flexibility and shape retention in typical ambient environments but is not intended for high-heat exposure
Chemical Properties
Mosaic Aero features ISO 10993-5 cytotoxicity approval, making it suitable for skin-contact applications such as orthotics and prosthetics. Its TPU foundation provides resilience, durability, and strong fatigue resistance under repeated loading.
Aero Material Specifications
Durable and easy to use. Explore Aero’s material specifications and key properties below.
DOWNLOAD DATA SHEET
Available Colours
Black
White
Green
Filament Specifications
| Parameter | Value |
| Diameter | 1.75 mm |
| Tolerance | ± 0.05 mm |
Printing Guidelines
| Slicer Profile | Available on canvas3d.io |
| Nozzle Temperature | 250°C |
| HEATED CHAMBER | Not Recommended |
| Build surface | Element Bed Type I, with glue stick |
| Special considerations | N/A |
Storage/Handling Considerations
| Hygroscopicity | Low |
| Drying Temperature | N/A |
| Drying Time | N/A |
Start Printing with Mosaic Aero
Aero in Action: Durable, Reliable, and Ready to Print
Materials Engineered for Performance
Explore Mosaic’s Line of High-Performance 3D Printing Materials.
Professional
Professional
High-performance 3D printing materials in bold colors for dependable, all-purpose use.
- Mosaic PLA
- Mosaic ASA
- Mosaic ABS
Flexible
Quickly iterate product designs using high-speed, multi-material printing that delivers functional, testable prototypes with minimal turnaround time.
Quickly iterate product designs using high-speed, multi-material printing that delivers functional, testable prototypes with minimal turnaround time.
- Validate designs faster with true-to-function parts
- Combine flexible and rigid materials in one print
- Reduce outsourcing and accelerate time to market
Light Industrial
Quickly iterate product designs using high-speed, multi-material printing that delivers functional, testable prototypes with minimal turnaround time.
- Validate designs faster with true-to-function parts
- Combine flexible and rigid materials in one print
- Reduce outsourcing and accelerate time to market
Industrial
Quickly iterate product designs using high-speed, multi-material printing that delivers functional, testable prototypes with minimal turnaround time.
- Validate designs faster with true-to-function parts
- Combine flexible and rigid materials in one print
- Reduce outsourcing and accelerate time to market
Array really automates 3D printing by making it a hands off procedure, I can send a print from my computer at home and not have to come into the office at 9pm – the parts are just sitting there ready for me the next day.
Connor Reddington, Avid (a Lubrizol Company)
Students at all levels of education should have access to an Array. It is essential if we’re encouraging STEM education, design engineering thinking, prototyping, iteration – students should have a reliable 3D printer to make parts in the volumes they need.
Cody Soska, Technical Specialist at IDeATe
The ability to develop and produce custom plastic parts at scale, on our factory floor, is great for our business and new client acquisition.
James McColl, Senior Program Manager Microart Services Inc.
Everything You Need to Know
Mosaic Aero benefits from slower print speeds to maintain consistent extrusion due to its flexible, low-density structure. Proper bed preparation can help with first-layer adhesion, and adding stabilization or support features may improve print quality on tall or thin parts. While Mosaic Aero has low moisture sensitivity, proper storage is recommended.
Download the spec sheet for detailed print settings and material information.
Mosaic Aero is a foaming, tunable TPU, its hardness, density, and feel can be adjusted through print settings. Unlike standard TPU, which has fixed properties, Aero can range from soft and compliant to firm and supportive, making it ideal for orthotics, prosthetics, cushioning, and robotics applications where adaptable performance is required.
Yes. Mosaic Aero’s mechanical properties are tunable by adjusting print parameters, which influence foaming behaviour and resulting part density. This allows a single spool to produce parts ranging from soft, cushioned components to firmer, more supportive structures.
Mosaic Aero is designed for skin-contact use cases and is well suited for orthotics, prosthetics, cushioning, and ergonomic components. Its elasticity and fatigue resistance make it a strong choice for applications that experience repeated loading and long-term use.
Download the spec sheet for detailed certifications, material properties, and application guidance.
Aero is more sensitive to machine parameters than standard TPU due to its flexible nature and foaming behaviour. It prints reliably on controlled systems using tuned parameters, especially adjustments to flow, temperature, and cooling. Once dialed in, it offers stable layer bonding and consistent foaming, enabling lightweight and cushioning structures not achievable with standard TPU.