3D-printed foam could provide alternative to polymer foam

The research from The University of Texas at Dallas focused on creating a sturdy but lightweight foam that could be 3D-printed, a method that is still largely unexplored in commercial manufacturing, said UT Dallas doctoral student Rebecca Johnson. The work is detailed in RSC Applied Polymers

“This is probably the longest project I’ve ever done,” said co-lead author Johnson. “From start to finish, it was a little over two years. A lot of it was trying to get the polymer formulation correct to be compatible with the 3D printer.”

Johnson said that making new materials that are compatible with 3D technology is challenging, but the 3D-printing process allowed the researchers to create complex shapes that could be customised in manufacturing applications. To demonstrate the proof-of-concept, they produced foam in the shape of a balloon dog.

“The goal of the project was to address some limitations in 3D printing in terms of making polymer foam,” said Dr. Ron Smaldone, associate professor of chemistry and biochemistry in the School of Natural Sciences and Mathematics and the corresponding author of the study. “One of the main uses, or interests, for 3D-printable foams is insulation and shock absorption.”