Mastering Variable Density Foam
Explore how our advanced 3D printing technology enables precise density control for superior foam customization and performance.
At NeoFoam, we harness the power of cutting-edge 3D printing technologies to revolutionize foam production. Central to our innovation is the ability to control foam density within a single product, a technique we've developed to offer unparalleled customization and performance.
Our unique Structural Density Control method allows us to adjust the firmness and flexibility of foam by modifying the thickness of the lattice across different areas of a single product. We achieve this through two approaches depending on the printing technology:
Structural Density Control
Using Rhino and Grasshopper parametric algorithms, we manipulate the beam diameters within a BCC lattice structure. Thicker beams result in firmer zones, while thinner beams create softer areas, enabling us to tailor the material properties to meet specific needs.
With our proprietary software, we modify the gcode generated by standard slicers. By adjusting the material flow, we alter the thickness of the gyroid lattice walls, providing control over the hardness or softness of different sections within the same product.
Create the object form with a uniform lattice structure
Apply the density map
Final model with variable structural density, ready for 3D printing
SLA and SLS
FDM
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Medical Devices
Custom orthopedic supports and prosthetics that perfectly adapt to the patient’s body, providing enhanced comfort and pressure relief where it’s needed most.
Automotive
Ergonomically designed seats that combine maximum comfort with durability, tailored to specific zones within the seating structure for better long-term support and fatigue reduction.
Furniture
Smart furniture cushions and mattresses with zoned comfort, adapting to body contours for superior relaxation and support, all while utilizing sustainable, customizable foam solutions.
Sporting Goods
High-performance gear such as protective padding and footwear that offer targeted flexibility and rigidity, improving both safety and performance for athletes.
Variable Density Technology opens up a realm of possibilities across various industries:
Ready to innovate?
Connect with our team to bring your foam product to life. Meet Kate, our CEO, and Nick, CTO, to discuss how we can support your production goals.
