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Foam LW (Lightweight) Technology is an advanced polymer modification and 3D printing material technology developed by eSUN. Designed specifically for weight-sensitive additive manufacturing applications, it enables printed models to reduce their weight by up to 50% compared to traditional solid materials.
Achieves up to 50% reduction in density, dropping model weight significantly while keeping structural form factor intact.
Uses micro-foaming agents that trigger inside the hotend during extrusion, expanding the printed line width dynamically.
Naturally diffuses layer lines during foaming, delivering an exceptional matte texture and easy-to-paint surface.
Requires significantly less filament by volume to print the exact same geometry compared to standard unfoamed plastics.
Unlike passive foaming materials that rely on pre-expanded microscopic hollow spheres embedded inside the raw filament, Active Foaming Technology dynamically expands during the heat melt phase inside the 3D printer hotend.
Foaming activation begins past threshold temperatures (typically 210°C–230°C depending on polymer base).
Gas bubbles expand uniform microscopic closed-cell structures inside the molten bead right as it exits the nozzle orifice.
Because the extruded material expands, the volumetric flow multiplier can be turned down to 50%–60%, saving material instantly.
The physical transformation during the active foaming process can be categorized into four key thermodynamic phases inside the print head extrusion path.
| Phase | State / Zone | Physical Mechanism | Resulting Effect |
|---|---|---|---|
| 1. Solid Feed | Cold End / Drive Gears | Standard solid filament, smooth drive feeding without slippage or crush. | Consistent volumetric input into melt zone. |
| 2. Thermal Activation | Melt Zone (>210°C) | Thermally sensitive blowing agent decomposes inside base polymer matrix. | Gas nucleation seeds form under pressure inside nozzle melt core. |
| 3. Extrusion & Expansion | Nozzle Exit / Die Swell | Pressure drops upon exit; gas bubbles expand rapidly forming closed micro-cells. | Line width increases while density decreases sharply. |
| 4. Solidification | Layer Cooling Phase | Micro-bubbles lock into place as polymer cools below glass transition temperature. | Lightweight, rigid structure with low thermal warping. |
By altering printing temperature and flow rate settings in your slicing software, users have precise, fine-grained control over the degree of foaming expansion and final object density.
| Printing Temperature | Foaming Ratio | Extrusion Flow Rate | Density Output | Typical Best Use Case |
|---|---|---|---|---|
| 190°C – 200°C | Unfoamed (0%) | 100% Flow | ~1.21 g/cm³ | High structural rigidity, fine detail features, structural joints. |
| 210°C – 220°C | Low Foaming (~25%) | 80% – 85% Flow | ~0.90 g/cm³ | Balanced strength and weight, general outdoor models. |
| 230°C – 240°C | Medium Foaming (~50%) | 65% – 75% Flow | ~0.70 g/cm³ | RC Aircraft wings, drone bodies, lightweight cosplay gear. |
| 250°C + | Max Foaming (~100%+) | 50% – 60% Flow | ~0.58 g/cm³ | Ultra-lightweight RC plane wings, low wing loading gliders. |
Weight reduction provides major aerodynamic and physical advantages, particularly for airborne RC aircraft, high-speed UAVs, and portable functional props.
Drastically decreases the stall speed of remote-controlled model planes, enabling agile low-speed flight and smoother glide performance.
Lighter airframe weight requires less motor thrust to stay aloft, extending flight times and battery endurance up to 30–50%.
Micro-cellular closed foam structure acts as internal micro-cushions, absorbing impact energy better than rigid solid plastics during hard landings.
Foamed prints sand effortlessly compared to standard solid polymers, allowing quick removal of support nubs and seamless bonding with standard cyanoacrylate (CA) glue.
eSUN has built a versatile lightweight material matrix based on different polymer backbones to cater to various temperature, flexibility, and strength requirements.
The flagship lightweight filament. Easy to print, low warp, up to 2x volume expansion ratio. Ideal for RC planes and lightweight props.
Optimized for high-speed CoreXY & modern high-flow printers. Maintains consistent thermal foaming performance even at elevated printing speeds.
Combines high temperature resistance (>150°C), mechanical toughness, chemical resistance, and lightweight cellular structure for demanding engineering UAVs.
Foaming elastic filament offering tunable shore hardness and ultra-lightweight flexible parts, suitable for lightweight footwear soles, RC tires, and vibration dampeners.
Foam LW material offers distinct visual and functional advantages over conventional 3D printing filaments during printing and finishing stages.
The volumetric cell expansion softens boundary lines between adjacent layers, resulting in a smooth, velvet-matte aesthetic natively out of the printer.
The slightly porous micro-texture provides an exceptional anchor surface for paints, primers, and adhesives without requiring heavy sanding.
Expanded gas cells relieve internal thermal stress during cooling, minimizing corner lifting and warpage on large thin-walled prints.
Micro-cellular edges fuse tightly when treated with standard superglue (CA glue) or specialized foam adhesives, providing ultra-strong joint lines.
From hobbyist aviation enthusiasts to professional drone manufacturers and prop creators, Foam LW technology empowers diverse high-value lightweight applications.
| Industry / Sector | Typical Application | Material Value & Benefit |
|---|---|---|
| RC Model Aviation | Fixed-wing RC aircraft, wing ribs, fuselages, tail fins, scale model warbirds. | 50% weight reduction lowers wing loading, increases flight agility, and enables realistic scale flight performance. |
| UAV & Drone Systems | FPV canopy covers, payload housings, aerodynamic cowlings, lightweight landing gear. | Extended flight endurance, enhanced shock absorption during emergency landings, high power-to-weight efficiency. |
| Cosplay & Prop Design | Helmets, armor suits, giant weapon props, wearable costume accessories. | Dramatically reduces wearable fatigue for long events; easy to sand, prime, and hand-paint. |
| Industrial Prototyping | Volumetric mockups, architectural scale models, lightweight ducting inserts. | Saves raw material costs per volume, speeds up printing time, and easy to handle during transport. |