Systems and methods for manufacturing a product include a mixing station for preparing a solution containing a base material and a performance modifier. The base material is configured to deliver performance characteristics of the product that are preselected and the performance modifier is configured to enhance the performance characteristics. An encapsulation station produces particles of the performance modifier in a coating of the base material as an encapsulate powder. An additive manufacturing cell includes an energy source and is used to build the product from the encapsulate powder by an application of energy from the energy source.

This disclosure relates to thermoplastic polyurethane (TPU) powders derived from expanded TPU and/or molding part thereof, wherein the average particle size D50 of the powders is no more than 1 mm, to a 3D molding formed from the same and to a process of forming the 3D molding. The TPU powders of the present invention can be used to prepare 3D products with low density, high rebound resilience and good mechanical properties, and the TPU powders of the present invention can be derived from a wide range of sources, and the TPU powders and 3D products of the present invention can be easily reused.

Systems and methods for manufacturing a product include a mixing station for preparing a solution containing a base material and a performance modifier. The base material is configured to deliver performance characteristics of the product that are preselected and the performance modifier is configured to enhance the performance characteristics. An encapsulation station produces particles of the performance modifier in a coating of the base material as an encapsulate powder. An additive manufacturing cell includes an energy source and is used to build the product from the encapsulate powder by an application of energy from the energy source.