Polymerization process promises to expand 3D printing universe
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Imagine the cost savings possible if a mattress could be compressed two to seven times its normal size before shipping, then, after being heated 60 seconds upon delivery, revert to regular size.
Walter Voit, founder of Adaptive3D, a Desktop Metal company, said a polymer resin for 3D printing that his company is developing brings such a scenario within reach. “You could have a mattress the size of an organic chemistry textbook that you could ship as a solid, dense piece of plastic, then, in 60 seconds, have it pop open to a king size mattress,” said Voit.
During an interview with the Additive Reporter at the RAPID + TCT show in May, Voit explained that the behavior of the material, called FreeFoam, is made possible by the photo PIPS (photopolymerization-induced phase separation) process. “Essentially, we have these little balloons that are about 2 microns big within the printed part,” said Voit. “When heated to 160 C, they evolve a gas—CO2—that blows up the balloons.”
Besides mattresses, other applications for FreeFoam include car seats, pillows, shoes, and medical devices.
Click here to a FreeFoam product video. 
