PrintFoam Announces High Throughput Foam 3D Printer

Building on its experience in foam 3D printing resins, PrintFoam aims to go big with revolutionary large format hardware.

WALES, Wis., May 17, 2022 /PRNewswire/ — In a world of 3D printed homes and furniture, the need for lightweight structured materials has never been greater. That’s where PrintFoam comes in – it’s a 3D printing resin startup that makes foam parts.

PrintFoam’s proprietary resins have been around for a few years now and have demonstrated incredible performance improvements in many applications where you would expect to find traditional foam solutions. Seeing these developments, other 3D printing companies have started to take notice. But to date, existing print platforms have been too slow to introduce this unique resin technology to exciting new markets.

We realized it would be possible to produce 3D printed foam sheets the size of plywood in minutes.

Matthew Person

PrintFoam aims to change that and take the field a step further by announcing the development of the first specialist printing hardware for printing foam on an industrial scale.

According to Mathew Pearlson, director and co-founder of Print Foam, the ah-ha moment came when he realized the need to ignore traditional vat-based printing techniques popularized by companies such as FormLabs, Carbon and Desktop Metal. “Using a combination of new optical patterning techniques, as well as moving away from a standard vat printing process, we realized it would be possible to produce 3D printed foam plywood sheets in minutes. .”

Everyone in the field is trying to mimic the behavior of traditional foams using plastic mesh… the computer is yelling at the engineer to stop what he’s doing and use a foam for the application .

David Walker

By accelerating their production times from hours to minutes, PrintFoam is able to enter a plethora of new markets previously unreachable with large architectural sized panels.

“It’s really remarkable, and I’ve never seen anything like it,” says Dr. David Walker – Co-founder of Azul 3D and Executive Chairman of the Photopolymer Additive Manufacturing Alliance. “Everyone in the field is trying to mimic the behavior of traditional foams using plastic lattices produced by computer models. These models keep telling engineers to generate lattices with smaller struts and unit cells smaller…essentially the computer is yelling at the engineer to stop what they are doing and use a foam for the application.We as a community have not listened and acted on this.

Designed from the ground up to meet the needs of its customers, the new system is expected to disrupt manufacturing with scale and speed that matter. According to Pearlson, “The new PrintFoam system expands our ability to provide complete solutions to our customers who are looking for ways to print large numbers of documents quickly without sacrificing resolution.” The technology is currently in limited beta access, but the company is actively accepting a limited number of new partnerships. PrintFoam is already working with customers to explore new approaches to noise mitigation, carbon sequestration, concrete construction, and more.

About printing foam

PrintFaom is a fast-paced additive manufacturing (AM) startup in the Milwaukee subway station. The company originated from MIT in 2016 with the goal of creating lighter and cheaper 3D printed parts by harnessing the power of foam materials. With a portfolio of proprietary materials and technologies, PrintFoam has provided solutions to customers in the automotive, aerospace, defense, oil & gas, and building materials industries. PrintFoam has received numerous competitive awards, including the MIT Sandbox Innovation Fund, the Radiation Technology Association’s RadLaunch Award, and the National Science Foundation’s Small Business Innovation and Research Grants.


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