FreeFoam™ | How It Works

FreeFoam resins contain a heat-activated foaming agent, and are 3D printed into parts like other resins with Digital Light Processing (DLP). However, these parts expand controlled air pores during a quick oven cycle, expanding the part 2-7 times their original size.

While 3D printers today can process standard polymers into lattice designs that replicate foam, FreeFoam is a true photopolymer foam material containing closed cells, delivering revolutionary benefits for the automotive, furnishing, sporting goods, and other industries.

Aside from eliminating the expensive tooling and waste associated with standard foam production, FreeFoam delivers a stronger strength-to-weight ratio that’s beneficial for reducing shipping costs and improving efficiency — while enabling new design freedoms.

FreeFoam can be optimized for a wide range of Shore values and will be commercially available in 2023.