In the field of veterinary medical devices, providing comfortable, durable, and body-conforming prosthetics for animals that have lost mobility has always been a significant challenge. Bionic Pets LLC is a globally leading provider of custom animal prosthetics and orthotics, dedicated to helping animals regain their mobility and independence.
Today, we take a closer look at a collaborative application case between Kexcelled and professional 3D printing solutions provider Raise3D. Discover how the combination of high-quality flexible filament and advanced printing equipment has enabled Bionic Pets to build a smarter and more efficient on-demand manufacturing workflow—helping countless pets run freely again.
Unique Lives, Unique Needs: The Challenge of Custom Veterinary Prosthetics
Bionic Pets provides a wide range of customized solutions for pets worldwide, including full-limb and partial prosthetics. Since every animal has a unique body shape, weight, and injury condition, traditional mass-production methods are unable to meet these personalized requirements.
To ensure prosthetics deliver both functionality and comfort, Bionic Pets faced several key challenges:
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Extreme customization requirements:
Each prosthetic must be precisely adjusted in thickness and hardness according to the animal’s weight, movement patterns, and usage conditions. -
Long production cycles:
Animals often require prosthetics urgently during rehabilitation. Previously, production could take anywhere from 6 to 48 hours, resulting in limited delivery efficiency. -
High durability with excellent comfort:
The material must provide outstanding tear resistance while maintaining a smooth surface finish and being safe, non-toxic, and comfortable for long-term contact with animal skin.
Strong Collaboration: Kexcelled TPU Perfectly Matches Raise3D’s New E3 Platform
To overcome production limitations, Bionic Pets adopted the newly released Raise3D E3 IDEX 3D printer and selected Kexcelled TPU flexible filament as the core material solution. This combination of advanced hardware and high-performance materials delivers unprecedented improvements in printing speed, surface quality, and customization capabilities.
- More Comprehensive! Covering 10 Hardness Levels (60A–77D):
Different parts of a prosthetic require different levels of flexibility and support. Through advanced molecular chain design, Kexcelled TPU achieves an ultra-wide hardness range from 60A to 77D, covering up to 10 hardness grades.
Bionic Pets can precisely select the optimal hardness for each application, such as the TPU 95A used in this project. The material effectively absorbs impact during running while maintaining long-term durability and structural stability.
- Easier Printing! Smooth Feeding with Reliable Performance (AMS-Compatible*)：
Through specialized processing technology, Kexcelled significantly reduces the surface stickiness of TPU filament, improving feeding smoothness (selected materials are also compatible with multi-color feeding systems such as AMS).
Combined with Raise3D E3’s newly developed FlexFeed flexible auxiliary feeding kit, this highly reliable filament system effectively eliminates filament jams and nozzle clogging issues. TPU maintains excellent print quality even at speeds of up to 200 mm/s.
- Double Productivity with Reliable Safety:
The powerful Independent Dual Extruder (IDEX) design of Raise3D E3 enables simultaneous production and effectively doubles manufacturing capacity, significantly reducing the cost per prosthetic component.
More importantly, as a wearable medical device material, Kexcelled TPU series has passed multiple international material safety certifications, including RoHS China, California Proposition 65 (CP65), TSCA, EU RoHS, UK RoHS, and REACH-SVHC, ensuring safe and worry-free long-term use for animals.
A Major Leap in Efficiency: Delivery in as Fast as 1 Hour with Extremely High Print Success Rates
With the combined advantages of Kexcelled high-performance materials and Raise3D printing technology, Bionic Pets established a highly efficient and stable on-demand manufacturing workflow:
- 82% Reduction in Production Time
Thanks to high-speed printing capabilities and dual-extrusion technology, the production time for a single component has been reduced to as little as 1 hour.
- Smart Detection, Near-Zero Material Waste
By combining a filament drying system to maintain optimal TPU conditions with Raise3D E3’s 9-point automatic bed leveling system (which intelligently detects the distance between the nozzle and build platform), the solution greatly improves first-layer adhesion and overall print success rates, effectively minimizing material waste.
Future Outlook: Empowering Innovation Through Material and Hardware Collaboration
By adopting the combined solution of Kexcelled high-performance TPU materials and Raise3D E3 3D printing equipment, Bionic Pets has successfully overcome traditional manufacturing limitations in veterinary prosthetics.
This collaboration represents not only a breakthrough in production efficiency and product quality, but also enables Bionic Pets to provide safer, faster, more affordable, multi-color, and highly customized solutions for more animals in need.
As a global supplier of innovative 3D printing materials, Kexcelled remains committed to developing high-quality, highly compatible filaments. In the future, Kexcelled will continue strengthening partnerships with leading hardware manufacturers such as Raise3D, leveraging the combined power of “materials + equipment” to empower more innovative companies like Bionic Pets—and help more lives regain independence and freedom through technology.