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Data-driven process maps for FAM published in Materials & Design

Updated
20/06/2026

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We are pleased to announce the publication of a new scientific article on Foam Additive Manufacturing in Materials & Design by Elsevier:

“Data-driven process maps for functionally graded foams in Foam Additive Manufacturing: Accuracy and interpretability across six models”

The paper presents a data-driven approach to predict and control foam density in FAM, based on a dataset of 528 PLA–CO₂ experiments. By comparing six predictive models, the study shows how process maps and machine learning can support the development of lightweight, mono-material and functionally graded 3D printed structures.

This publication further strengthens Oniro’s scientific roadmap toward advanced FAM software, digital process navigation and industrial applications where weight reduction, material efficiency and local mechanical tuning are key.

Other publication

24/02/2026

Fracture toughness and auxeticity in disordered metamaterials

13/02/2026

Sensor-Integrated Soft Actuators with Foam Additive Manufacturing

29/04/2025

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

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.

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