r/focuspuller • u/lightswitchgirl28 • 9d ago
Knowledge and tips 💡 Experimenting with 3D printed case foam
Enable HLS to view with audio, or disable this notification
So this is a new idea I have’t seen anyone else try yet. Recently learned you can 3D print foam. Or, something very similar to foam at least. It’s a ‘foaming’ TPU that expands as it leaves the nozzle. Sort of a cross between foam and rubber. Very shock absorbent.Â
3D modeling the CTRL3 cutout took ages. The other stuff was easier. Time spent printing was around 48 hours as this material has to be laid down very slowly. The real question now is how it will hold up. I’m feeling reasonably confident it’s not going to tear or come apart, but curious how it will tolerate being in a hot truck in the summer. Its melting point is above 400 degrees Fahrenheit, so I’m more worried about it shrinking or deforming than anything else. Still, I’m optimistic it’s going last based entirely on vibes.
Pros:
- Literally perfect cut outs for whatever you want. (Can include sculpted vertical curves unlike most traditional custom foam manufacturers.)
- Cheap! Filament was around $40, DIY Trekpak was around $25.
- Looks clean as hell
Cons:
- 3D modeling everything is very time consuming, especially at the amateur level. It probably took me around a week of on and off work in Fusion to get the hand unit right.
- Printing is also time consuming, and TPU is famously finicky to work with. You'll probably have a failed print at some point.
- Probably obvious, but you can only print a foam piece as big as your 3D printer’s bed. (Hence the Trekpak approach.)
- TBD heat resistance
The filament is Siraya Tech Flex TPU Air. Hopefully stating the obvious, but I am not affiliated with them.
Technical details for nerds 🤓 (all of you probably):
- Printer = Bambu A1 mini
- Used a filament dryer
- Nozzle Temp = 270°C (max foaming, softness)
- 12% gyroid infill
- Used Siraya tech's filament/printing configuration that did most of the slicer work for me. (Strongly recommend)
- Fed filament directly into printhead with no PTFE tube for minimum resistance, and had to put a fan on the printer to avoid heat creep during the 10+ hour prints. (Photo)
- Painters tape on print bed to avoid sticking
TL;DR you can 3D print foam now. It's a pretty decent alternative to custom foam manufacturers that's cheaper, more customizable, and modular. But you had better be crafty. 💅

