Prusa Research Expands Filament Lineup with Actively Foaming Prusament PLA Lightweight

Prusa Research has introduced Prusament PLA Lightweight, a new actively foaming filament designed to produce parts with significantly reduced mass. According to the manufacturer, the material uses heat-activated additives inside the nozzle to expand the extruded polymer, resulting in a low-density, foamy structure that can yield up to three times more printed volume from a single spool compared to conventional PLA.

Key Technical Details and Foaming Properties

Prusament PLA Lightweight is designed for applications where minimising weight is critical, such as radio-controlled aircraft, drone components, floaters, and large cosplay props. The manufacturer states that the material can achieve up to a sixty-five percent reduction in weight compared to standard PLA.

The degree of expansion and final colour are directly tied to nozzle temperature. Prusa’s supplied profiles initiate foaming at 215 °C, reaching maximum expansion and the palest colour shades around 235 °C. Temperatures exceeding 250 °C are not recommended due to the risk of material degradation and potential fumes. Because the active foaming process causes increased polymer expansion, users should expect higher nozzle ooze and stringing during travel moves, which can be mitigated through slicer adjustments such as sequential printing or enabling avoid-crossing-perimeters settings.

The filament yields a matte, textured surface finish that helps conceal layer lines, giving prints an appearance similar to selective laser sintering components. Initial colour options include Army Green, Chocolate Brown, Galaxy Black, Natural, and Coral Orange, though the active foaming process results in a lighter, more muted tone on the finished print. Prusa recommends drying the hygroscopic material at 55 °C for five hours prior to use.

What This Means for South African Makers

Lightweight foaming filaments open up practical possibilities for local hobbyists and engineers working on RC models and wearable props. Because a single spool produces significantly more printed volume, makers can complete larger projects with fewer filament changes. However, successfully printing with lightweight PLA requires careful calibration of the extrusion multiplier and temperature profiles to prevent overextrusion or under-extrusion, making initial calibration prints essential before tackling complex designs.

DC3D’s Take

Actively foaming PLA is a useful specialty material for specific niches, but it requires patience to dial in correctly. The requirement to adjust extrusion multipliers based on precise temperature targets means it is not a drop-in replacement for everyday printing. For makers willing to tune their slicer settings, manage stringing, and handle calibration cubes, lightweight filaments offer a reliable way to cut down part weight without sacrificing structural volume.