I've been trying to print Mega Construx scale figures with full articulation and just haven't been happy with the results so far. I could get figures that looked great but the articulation wasn't there. I've printed in ABS and in various resins trying to get the right fit and look. Today, I tested printing with TPU and I have to say, I'm very pleased with the results so far. I need to do some tweaking on some settings to cut down on stringing, but as far as parts fit and everything, wow.
The attached pics are straight after printing, absolutely no cleanup or post processing done; the only work done was removing the supports.

As you can see, the parts are kind of 'hairy' from stringing and excessive flow I need to tweak but they fit together well. The only parts not printed in TPU are the head, waist & T-bar, and sword. The head, waist, and T-bar are Mega, the sword is one of my designs printed in resin:


Showing that the articulation is fully functional:


More articulation:


The parts are stiff and rubbery, similar to PVC and they hold their shape well. The hands can hold weapons and not drop them. The head fits snugly on the neck ball, while still being able to pivot and turn. One of the next tests I'm hoping to try is print-in-place with a dual extruder, printing the body parts in TPU and the connectors (elbow, shoulder, and T-post) in ABS.

Very nice!!

Thanks! I printed all the pieces at the same time on the platform and should have just done a couple pieces at a time to try it out. Once I get the retraction dialed in, I'm hoping to get some really nice pieces.

A second print run, this time just the torso. I printed it by itself to cut down on the movement of the printhead and cut down on the stringing. Just like the first figure, I did no post-processing other than removing any support material - no cleaning up extra material, no smoothing layer lines, just cut off the supports and assemble. Torso is my print and design, rest of the pieces are Mega Construx He-Man to show part compatibility.

Some minor layer issues just below his chest and a few layer lines evident, but overall, I'm really happy with this. I could put together a figure using this torso and be happy:


Showing he has full posability between the manufactured parts and my part:


He even has head tilt! More of the layer banding visible here. I printed at .1mm layer height and slow speeds but I may need to play with it some more:


Back view. He can wear a backpack if he needs to:


I slapped a thin layer of paint on him to make details (and flaws) more visible: