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Controlling Impact Behavior Through Foam Additive Manufacturing – Research Published by Springer

Updated
29/04/2025

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Peer-reviewed research by the Department of Chemical, Materials and Production Engineering (DICMaPI) of the University of Naples Federico II, in collaboration with the University of Messina, and published in Progress in Additive Manufacturing (Springer Nature), demonstrates how impact resistance can be tuned in mono-material structures by adjusting process parameters during Foam Additive Manufacturing (FAM).
The study highlights how structural performance can be controlled without changing the material — unlocking new possibilities for lightweight, recyclable components in aerospace, packaging, and structural design.

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This project was made possible thanks to the funding received under the “Campania Startup 2023” call for proposals, promoted by the Regional Department for Research, Innovation, and Startups (UOD05 – Regione Campania), as part of the Regional Operational Programme FESR 2014–2020 – Specific Objective 1.1 – Action 1.1.3.
This strategic support enabled us to formalize Oniro S.r.l. and initiate the industrial development of our core technology: Foam Additive Manufacturing (FAM), an advanced 3D printing process capable of controlling the internal morphology and density of thermoplastic materials through real-time physical foaming.

The project presented under the Campania Startup 2023 program aimed to demonstrate the potential of mono-material structural components manufactured in a single step, without adhesives or post-processing, offering high mechanical performance and full recyclability. Applications range from lightweight sandwich panels for transportation and aerospace to bio-based foamed parts for sustainable consumer products.
Thanks to this grant, we were able to invest in early-stage prototyping, intellectual property protection, and validation of our approach—laying the foundation for what is now an operating startup with international ambitions and solid technical credibility.

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Progetto realizzato con il sostegno finanziario – PR Lazio FESR 2021-2027 – Obiettivo Specifico 1.3. – Open Call ESA BIC Lazio – CUP F87H25001650008