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esun wiki eSUN Features Featured Material Technologies Foaming Technology

Foaming Technology

Technology Type: Lightweight Foaming Technology

Controlled Lightweight Foaming Technology for FDM 3D Printing

Foaming technology activates the foaming agent within the material during the printing process. At the moment of extrusion, the foaming agent expands and forms a uniformly distributed microcellular closed-cell structure inside the printed part.

Applicable Materials

PLA-LW ASA-LW PETG-LW

Core Values

Weight Reduction · Lightweight Structures · Material Efficiency · Functional Design

01 | Technology Overview & Mechanism

Core Printing Mechanism

Foaming Agent Activation ↓ Rapid Expansion During Extrusion ↓ Microcellular Structure ↓ Lower Material Density ↓ Lightweight Parts

High Expansion Ratio

PLA-LW material can achieve a foaming expansion ratio of more than 2.5×.

Significant Weight Reduction

Reduces the weight of finished same-size parts by more than 50%.

Material Efficiency

Enables larger printed volumes with significantly lower material consumption.

02 | Patented Technology

Patent Title

Controllable Lightweight Foaming Materials for FDM Printing, Preparation Method and Applications

Patent No.: ZL202110492412.1

2.5×
Foaming Expansion Ratio
>50%
Weight Reduction (Same-Size)

03 | In-Situ Foaming Process Workflow

Polymer Matrix + Foaming System
→
Heating & Melting
→
Foaming Agent Activation
→
Rapid Nozzle Expansion
→
Lightweight Printed Component

04 | Major Applications

Aerospace

Applications: UAV/drone bodies, lightweight structural components, internal parts.

Value: Improves flight efficiency and extends operating endurance.

Footwear & Apparel

Applications: Customized shoe midsoles, lightweight cushioning structures.

Value: Provides customizable cushioning and flexible structural design.

Automotive

Applications: Lightweight interior components, functional structural parts.

Value: Cost-effective approach to customized automotive weight reduction.

05-06 | Foaming Technology Comparison

Foaming Tech Core Mechanism Typical Applications Key Characteristics
Supercritical Gas Gas dissolution & pressure expansion PLA, ABS, PEEK Fine cellular structures, controllable
Mechanical Direct gas incorporation Flexible materials, TPEs Physical gas introduction
Chemical Chemical decomposition generates gas PLA, ABS, TPU In-situ gas generation
Physical Temp/pressure-induced expansion Thermoplastics, resins No chemical gas-generation reaction
eSUN Controlled Controlled activation during extrusion PLA-LW, ASA-LW, PETG-LW High expansion ratio, lightweight FDM parts

08-09 | eSUN Lightweight Foaming Materials

PLA-LW

Lightweight foaming PLA designed for controlled expansion during FDM printing.

ASA-LW

Lightweight foaming ASA combining weather-resistant ASA characteristics with weight reduction.

PETG-LW

Lightweight foaming PETG combining PETG toughness and chemical resistance with weight reduction.

Explore More: FDM Materials · Lightweight Materials · Material Technologies · PLA Materials · PETG Materials · ASA Materials