3D printer manufacturerDesktop Metalhas debuted FreeFoam, a new 3D printable photopolymer resin family that contains heat-activated foaming agents.
Invented by Texas-based materials specialistAdaptive3D, a Desktop Metal subsidiary acquired in 2021, FreeFoam can be programmed to expand anywhere between 2 to 7 times its original printed size without any tooling. The result is the production of tunable and durable closed cell foam parts, which are expected to see extensive use in sectors such as automotive, furniture, sporting goods, footwear, and healthcare.
Initially available exclusively on theETEC Xtreme 8KDLP 3D printer, FreeFoam will be showcased atFoam Expo North Americain Michigan from June 28-30. The Expo will feature a 3D printed FreeFoam car seat developed in partnership withCamaco.
“FreeFoam is one of the most exciting and commercially significant photopolymer solutions to come to market in the industrial printing space in years,” said Ric Fulop, founder and CEO of Desktop Metal. “The market for conventionally manufactured foam has many challenges – from expensive molds that limit designs to dense and heavy foams that absorb water and are expensive to ship and drive, to the inability to easily dial in strength and Shore hardness values in specific foam designs.”
The expansion of Desktop metal
Based in Massachusetts and founded in 2015, Desktop Metal quickly became well-known in the additive manufacturing sector for its portfolio of metal binder jet 3D printers. Sincegoing public on the NYSEin December 2020, the company has gone through a period of rapid growth with a plethora of acquisitions.
The expansions include theestablishment of Desktop Healthandwood 3D printing firm Forust. The firm bought out DLP 3D printer OEMEnvisionTEC in January 2021, which was rebranded to ETEC shortly after. Desktop Metal also acquiredrecoating system developer Aerosintandhydraulics firm Aidroa few months later.
August 2021 saw one of Desktop Metal’s biggest plays yet, when it announced theacquisition of competing binder jet 3D printer OEM ExOnefor $575 million. The deal was approved in November, combiningtwo of the industry’s leading binder jet firms.
3D printing custom foam parts with FreeFoam
According to Desktop Metal, more than 1.5 billion lbs. of foam is produced every year for bedding, seating, and a whole host of furnishing products. Conventional foam production involves cutting blocks of foam into smaller shapes as needed, which places a huge limitation on the geometries that can be produced while also resulting in significant waste from the trimmings.
Developed as part of Desktop Metal’s DuraChain product line, FreeFoam is designed to address these issues, enabling manufacturers to 3D print their foam products in any shape they desire. The resin can be 3D printed like any other via the DLP process, and expanded on-demand when heated at temperatures of 160 – 170°C in an oven.
The key to FreeFoam is the dispersed foaming agents contained within, which create closed cell pores throughout the material’s microstructure. These pores can expand to up to seven times their printed sizes depending on the exact grade of resin. Desktop Metal intends to offer several grades of the offering with different Shore hardness values and other properties such as water resistance.
Ultimately, customers will be able to 3D print parts much larger than the build volumes of the printers used to print them, slashing shipping space requirements and saving on logistical costs.
Fulop adds, “We’re especially excited to reveal our FreeFoam innovation in Metro Detroit, where our new foam material can help lightweight cars and trucks while preserving the performance and comfort expected in foam seating. With FreeFoam, Desktop Metal is ready to liberate the foam market from its many challenges.”
FreeFoam is set for broad commercial availability in 2023.
订阅3D Printing Industry newsletterfor the latest news in additive manufacturing. You can also stay connected by following us onTwitter, liking us onFacebook, and tuning into the3D Printing Industry YouTube Channel.
Looking for a career in additive manufacturing? Visit3D Printing Jobsfor a selection of roles in the industry.
Featured image shows a 3D printed FreeFoam car seat before (left) and after (right) expansion. Photo via Desktop Metal.
