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Foam Additive Manufacturing of Thermoplastic Polymers – Research Published by Elsevier

Updated
17/07/2024

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Peer-reviewed research conducted by a multidisciplinary team from the Department of Chemical, Materials and Production Engineering (DICMaPI) of the University of Naples Federico II, published in the Journal of Manufacturing Processes (Elsevier), provides the first comprehensive mapping of how process parameters influence foam morphology in Foam Additive Manufacturing (FAM).
The study investigates the role of six key variables β€” including gas absorption and desorption times, extrusion temperature and speed, nozzle diameter, and gas pressure β€” in tailoring foam density, bubble size, and distribution within 3D-printed strands. By revealing how each parameter affects micro- and macro-structure, the work offers a practical guide for engineering lightweight, recyclable components with controlled properties, advancing applications in aerospace, biomedical, packaging, and structural design.

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This project was made possible thanks to the funding received under the β€œCampania 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 approachβ€”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