FreeFoam™

ETEC DLP 

FreeFoam™ 

Produce durable and dimensionally accurate closed cell foam parts without tooling

FreeFoam™ is an expandable photopolymer resin that contains dispersed heat-activated foaming agents that can be 3D printed into parts with Digital Light Processing (DLP) 3D printing technology. After printing, FreeFoam parts are briefly placed into an oven which creates closed cells that expand the part from 2 to 7 times its original size.

A Revolution in the
Foam Industry

Remove the barriers and waste associated with
traditional foam manufacturing

FreeFoam resin enables a range of benefits where foam is prevalent, including in the automotive, furnishing, footwear, and sporting goods industries. With the ability to 3D print closed-cell foam parts without tooling, you are able to reduce waste and increase design complexity and part performance.  FreeFoam will be available in a range of grades and is 3D printed similar to other photopolymer resins using Digital Light Processing (DLP) technology.

SPEAK TO AN EXPERT

 

Applications

Proto3000_Icon_Foam Replacement

Foam Replacement

Use in place of traditionally manufactured foam

3D printing Production Parts

Production Parts

Produce foam parts on-demand without tooling in low-mid volumes

Rapid Prototyping icon

Rapid Prototyping and Functional Testing

Prototype complex foam designs ready for rigorous testing at breakneck speeds

Consumer goods shoe icon

Consumer Goods and Electronics

Create customer-centric highly customized experiences with improved function and performance

Proto3000_Icon_Complex Geometry_1

Complex and Lightweight Foam Structures

Design foam structures that would be impossible to produce with traditional CNC and cutting processes

Functional parts icon

Supply-Chain Optimization

Build parts when and where you need them while reducing the shipping volume of goods through heat-activated expansion

FreeFoam Process Workflow

3D printing foam parts with FreeFoam material has a similar workflow to other DLP resins.

ETEC Xtreme 8K large format DLP 3D printer

DESIGN + PRINT

Design complex foam lattice structures with any design engine
and 3D print the parts on the ETEC Xtreme 8K DLP 3D printer

Finishing 3D Printing Post Processing

CLEAN + POST PROCESS PARTS

Remove excess resin from the 3D printing process

Proto3000_Icon_Temperature Raise

PLACE PARTS IN OVEN

Heat parts in an oven at 160-170°C (320-340°F). Parts expand 2-7 times the original size, depending on material grade, in minutes

FOAM PARTS ARE COMPLETE

Foam parts are complete with the right density and sizing

Material Highlights

Material Characteristics

Hardness (Shore A) –
60 ± 10, ASTM D2240

Volumetric Expansion Factor (m³/m³):
3.6 +/- 0.3, A3D Internal

Expanded material density (g/cm³):
0.28 +/- 0.04, A3D Internal

Tear Strength (kN/m):
> 10, ASTM D624 Die C

Uses

Foam replacement

Cushions, padding, and support

Shock and pressure absorbing applications

Footwear, apparel and consumer goods

Packaging and transport

Seating, furniture and mattresses

Industries

Industrial goods

 Consumer goods

Healthcare

 Education

Aerospace

Transportation and Automotive

Performance Scale

Strength to Weight Ratio
Flex and Compression
Tear Strength

Material Color

hex White

Additive Manufacturing with Light

Discover the speed, throughput, and material capabilities of the
Digital Light Processing (DLP) 3D printing process

Explore

Technical Specifications

 
Standard/Test Method
Value
Hardness (Shore A)
ASTM D2240 60 ± 10   
Volumetric Expansion Factor (m³/m³)
A3D Internal 3.6 +/- 0.3   
Expanded material density (g/cm³)
A3D Internal 0.28 +/- 0.04   
Elongation at break (%)
ASTM D638 Type V 125 ± 25   
Tensile Strength (MPa)
ASTM D638 Type V > 4   
Tear Strength (kN/m)
ASTM D624 Die C > 10   
Operating temperature (°C)
ASTM D4065 -55 to 105   
Compression Set (%) @ 25°C
ISO 1856-A < 15   
Volatile Organic Compounds (VOC) (µg/g)
GMW-15634 < 400   
Semi-Volatile Organic Compounds (SVOC) (µg/g)
GMW-15634 < 250   
Burning Rate (mm/min)
UL 94-HB < 95