3D-printed heat-activated foam to be unveiled for cars, shoes and more

Desktop Metal Inc (DM.N) plans to unveil a type of foam that the U.S.-based industrial 3D printer maker claims could significantly change the way athletic shoes, automotive seats and other products are produced.

According to a company statement viewed by Reuters, a new type of photopolymer resins or foam dubbed FreeFoam can be 3D-printed to the desired design in a compact form, which will be on display next week at a Michigan trade show.

The 3D-printed foam can be heated and expanded later on-demand in an oven close to the final point of use or assembly, helping manufacturers – from athletic shoe makers to furniture producers to car-seat makers – save shipping and inventory costs.

3D printing, also known as additive manufacturing, is a technology that allows complex shapes to be built up in layers from particles of plastics or metal, viewed by Washington as a sort of innovation that will enable U.S. manufacturers to flourish and create jobs.

Conventionally manufactured foam has had many challenges, said Ric Fulop, founder and chief executive officer of Desktop Metal, which has auto giants BMW and Toyota Motor Corp and private rocket company SpaceX among its clientele.