3D-Printed TPU Single-Material Headrest in a Car Interior

Additive Manufacturing in Vehicle Interiors Headrests made from printed monomaterial

2026-03-02 From Matthias Gutbrod 3 min Reading Time

As part of the Vision O circular strategy, Škoda Auto is demonstrating the potential of additive manufacturing for mass production. By using Ultrasint TPU in a honeycomb structure, the company is able to combine complex mechanical requirements—such as damping and dimensional stability—in a single component without relying on conventional composite solutions.

The interior of the Skoda Vision O concept car was designed specifically with the circular economy in mind. The TPU headrest, which was manufactured using additive manufacturing, can be sent directly for recycling at the end of its life cycle.(Bild: Skoda) — The interior of the Skoda Vision O concept car was designed specifically with the circular economy in mind. The TPU headrest, which was manufactured using additive manufacturing, can be sent directly for recycling at the end of its life cycle.
(Bild: Skoda)

At the heart of the newly developed headrest is Ultrasint TPU, a thermoplastic polyurethane that BASF developed specifically for powder-bed-based additive manufacturing processes such as the selective laser sintering (SLS)—and is marketed under the Forward AM brand by Mass Additive Manufacturing. For the user, the material offers the advantage of high process stability and excellent surface quality of the printed components.

High-Performance Polymer for Additive Mass Production

When used in the Vision O, the polymer meets all requirements for comfort and durability within a single material system. Since it is a single-material component, it can be sent directly for recycling at the end of its life cycle without first having to separate different plastics or foams. This significantly reduces the complexity of the disposal chain and supports efforts to achieve a higher recycling rate in the automotive sector.

Functional Integration Through Graded Honeycomb Structures

The headrest’s design takes advantage of the creative freedom offered by 3D printing to achieve a functional gradation. The chosen honeycomb geometry is not static but varies in density across the component. The structure gradually opens up from a solid, mechanically stable base at the bottom to a large-pored, airy architecture in the upper section.

Additiv gefertigte Kopfstütze aus Ultrasint TPU — Design and honeycomb structure of the headrest in the Skoda Vision O.
(Source: Skoda)

This structural design results in specific deformation behavior: The open structure responds precisely to compressive loads and offers a soft, cushion-like feel. “The goal was a single-material headrest, which means reducing the number of components to a single material that meets all requirements,” according to the project managers at Škoda. This eliminates the traditional combination of a load-bearing plastic core, foam padding, and a fabric cover.

Sustainability Through Zero-Waste Production

In addition to material recyclability, the process stands out for its resource-efficient manufacturing. The Ultrasint TPU printing process is designed as a zero-waste production process. Unused powder in the build volume can be reused in subsequent print jobs, which increases material efficiency compared to subtractive processes or traditional injection molding with gate losses.

Karsten Schnake, a member of the Škoda Auto Executive Board responsible for procurement, emphasizes the importance of this holistic approach: “We carefully examine how components are procured, manufactured, packaged, and transported. With the Vision O, we have worked on a closed-loop system that minimizes environmental impact.” This strategy demonstrates that additive manufacturing and TPU materials are key components for meeting upcoming regulatory requirements such as the End-of-Life Vehicles (ELV) Directive.

Sitzbezüge im Skoda Vision O — The seat covers are manufactured as flat-knit fabrics with different textures, all in one piece. This ensures a perfect fit. They are made from 100% recycled polyester.
(Source: Skoda)

The automaker is also utilizing new manufacturing techniques for the seat covers: The materials are produced in a single piece as flat-knit fabric with various integrated structures. This ensures an optimal fit while also increasing durability. The material used is 100% recycled polyester (Rec PES), which is derived from recycled PET bottles. The process involves cleaning, shredding, and melting the recycled material into yarns, which are then woven into textiles.

Conventional Manufacturing vs. the Single-Material Approach

Traditionally, headrests in automotive manufacturing are highly complex assemblies made up of a wide variety of different materials. Škoda’s new design breaks with these conventional manufacturing structures in order to optimize both production and subsequent recycling.

Typically, a headrest consists of an injection-molded base made of rigid plastic (e.g., PA or ABS), a cushion core made of polyurethane foam (PUR), and a cover made of fabric or leather. This multi-material construction requires a multi-step process: injection molding of the base, foaming of the core, and subsequent covering. Recycling is also complex: at the end of the product’s life cycle, these firmly bonded components can only be separated with great effort, which makes material recovery difficult.

In contrast, with the Vision O, Škoda has reduced the number of components to a single material. Additive manufacturing makes it possible to replicate the mechanical properties—which are otherwise achieved through the use of different materials (hard core, soft foam)—solely through the geometry of a 3D-printed honeycomb structure.

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With this technological leap, the Vision O demonstrates that the plastics industry is on the verge of a transformation: moving away from tool-dependent assembly of complex hybrid components toward functionally integrated, one-piece manufacturing.