Standard melamine foam acoustic panels look utilitarian and are limited to simple shapes. 3D printing from thermoplastic polyurethane (TPU) and polyamide creates sound-absorbing elements with complex cellular structures tuned to specific frequencies. For reception areas this turns acoustic treatment into a design feature. Noise reduction coefficient NRC 0.75–0.95 — 30% higher than flat equivalents.
Technology and Materials
Panels are printed using FDM or SLS from TPU (Shore 60A–85A) with Kelvin or Gyroid cell structures. Cell size: 4–12 mm — selected to target specific frequency ranges. For speech frequencies of 250–4,000 Hz the optimum is 6–8 mm. Panel thickness: 30–80 mm. Standard module: 600×600 mm, weight: 0.8–1.5 kg.
For areas with strict fire safety requirements (Class B-s1,d0), PA12 polyamide with flame-retardant additive is used. Colours range from white and grey to the full RAL palette. Mass pigmentation or spray finishing available.
Advantages Over Traditional Solutions
Gradient cell density allows a single panel to absorb both low frequencies (125 Hz — HVAC hum) and high frequencies (4,000 Hz — speech). Traditional foam operates in a narrow band. The structure is computed from an acoustic model of the room: software identifies dominant frequencies and generates optimal cell geometry.
Visually, the panels resemble art objects: organic forms reminiscent of corals or honeycombs become interior focal points. For hotels and Class A business centres, this is where engineering and design become inseparable.
Panel lifespan exceeds 10 years: TPU polymer is resistant to UV, moisture and mechanical damage. Unlike melamine foam, it does not crumble or release microparticles — a critical advantage for medical facilities where air purity standards are strict.
Installation and Pricing
Panels attach to walls or ceilings using hidden magnetic fixtures or adhesive mounting. Removal without substrate damage. For suspended ceilings — drop-in to 600×600 mm grid. Installation of a 20 m² zone: 4–6 hours.
Cost per 600×600 mm TPU module: from $48. PA12 (fire-rated): from $72. Full acoustic treatment for a 100 m² lobby (walls + ceiling): from $2,800. Lead time: 2–4 weeks. Warranty: 5 years.