How can products be compelling before they even exist? This is exactly where 3D visualization comes in: It makes ideas tangible long before the first prototype is manufactured, thus becoming an integral part of a design thinking process.

This project with Covestro began with a material of great potential: Desmopan, an innovative thermoplastic polyurethane (TPU) with high durability, excellent damping properties, and variable hardness levels, completely free of plasticizers, and both mechanically and chemically recyclable. However, this material quality comes at a price. The key question was therefore: How can a product or system be developed that creates a legitimate cycle for the material, is sustainable, and reduces costs in the long term?

The healthcare sector, where enormous amounts of waste are generated annually by single-use products, presented itself as a suitable application area. The idea: to further develop existing concepts of 3D-printed medical splints using Desmopan. After a fracture, a scan of the affected body part could be performed following an X-ray, and a custom-fitted splint could be printed within minutes – robust, flexible, and leveraging the advantages of TPU over traditional plaster. While plaster is disposed of after a single use, the TPU splint could be removed by medical professionals after use and returned to a legitimate material cycle as a recyclate via chemical recycling.

Our task was to make this non-existent product visible: from its material feel and fit to its application in medical practice. 3D visualization transforms an abstract idea into a tangible concept – a tool that facilitates decisions, simplifies communication among all stakeholders, and guides the creative process from the initial sketch to a market-ready product. The project was developed as part of a university collaboration with material manufacturer Covestro.