Rosa3D Launches Foaming PLA and TPU

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April 4, 2026 News 9428

Polish filament manufacturer Rosa3D has recently introduced two active foaming filaments: PLA LW Aero and TPU Flex LW.

These materials expand when heated during printing, thanks to an embedded foaming agent, enabling the production of porous, lightweight parts.

PLA LW Aero begins foaming at 220°C and expands to 2.5 times its original size between 240–250°C, with a density range of 0.46–0.52 g/cm³. TPU Flex LW foams at around 260°C. Users can control the expansion level and print density by adjusting temperature and flow rate, with a recommended flow reduction to approximately 40% for maximum foaming.

Print speeds for both filaments should be kept between 5–60 mm/s to ensure uniform expansion. The advantage of active foaming materials lies in their ability to achieve variable densities as needed, allowing more printed output per spool compared to pre-foamed alternatives. While active foaming introduces additional variables to the printing process, it offers greater flexibility in density control.

PLA LW Aero is available in five colors in 1 kg refills, plus a white 0.5 kg spooled version. TPU Flex LW comes in four colors on 0.7 kg spools, with prices ranging from approximately €36–39/kg. Both products are suitable for applications requiring lightweight parts such as RC aircraft and drones, though users should note that thin-walled components may deform under high-temperature conditions.