With Freefoam, Desktop Metal wants to revolutionize the way foam products are made. This new family of photopolymer resins produces durable and dimensionally accurate closed cell foam parts without tooling.

Freefoam is a new family of photopolymer resins containing heat-activated foaming agents that are 3D printed with Digital Light Processing (DLP). After printing, the parts are briefly put into an oven where the foaming agent creates closed cells inside the material in a tightly controlled process.

This material can be programmed to expand a specific amount between two to seven times its original printed size — allowing the parts to be shipped in a compact form and expanded on-demand in an oven close to the final point of use or assembly, saving shipping and inventory expenses.

In addition to eliminating tooling and the waste associated with standard foam production, Freefoam enables new design freedom and delivers a high strength-to-weight ratio that produces light, high-performing parts that can reduce shipping costs and improve efficiency in cars and other products, the company states.

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