One of the biggest challenges with 3D printed cosplay isn’t the printing—it’s wearing it.
Most cosplay props are printed in PLA because it’s inexpensive, easy to print, and produces excellent detail. The downside is that large props, helmets, and armor can become surprisingly heavy over the course of a full convention. On the other hand, traditional TPU is incredibly durable and flexible, but it’s often too soft for armor and other structural cosplay pieces.
That led us to ask a simple question:
Can foaming TPU combine the best qualities of both materials?
To find out, we tested SainSmart’s new Lightweight Foaming TPU Air by printing several real-world projects and comparing them directly against both PLA and conventional TPU.
What Is Foaming TPU?
Unlike conventional TPU, foaming TPU contains a foaming agent that activates during printing. As the filament exits the nozzle, it expands, creating microscopic air pockets throughout the print.
Instead of reducing weight by lowering infill, the material itself becomes less dense while maintaining the overall dimensions of the part.
According to SainSmart, the material offers several advantages:
- Up to 50% lighter finished parts
- Up to 172% material expansion
- One spool can produce roughly the same print volume as about two spools of conventional TPU
- Adjustable firmness by changing print temperature
- Soft matte finish
- Excellent flexibility and impact resistance
Those are impressive claims—but we wanted to see how they translated into actual projects.
Test One: Orc Mask
Our first comparison was an Orc mask that had previously been printed in PLA.
The PLA version produced excellent detail, but it also carried significantly more weight. The foaming TPU version retained much of the sculpted detail while dramatically reducing the finished weight.
Weight Comparison
|
Material |
Weight |
|---|---|
|
PLA |
9.5 oz |
|
Foaming TPU |
5.3 oz |
That’s more than four ounces saved on a single wearable prop.
While the PLA print produced slightly cleaner details straight off the printer, the foaming TPU still captured facial features, skin textures, and surface detail remarkably well—especially considering the material is expanding during printing.
As we became more familiar with the print settings, overall print quality continued to improve.
Test Two: Stormtrooper Helmet
Helmets are where weight becomes a serious consideration.
Even a few ounces removed from a helmet can make a noticeable difference after several hours of walking around a convention.
Although our printer wasn’t large enough to produce a full-size helmet, the scaled version demonstrated just how lightweight the material can be.
The completed helmet weighed only 6.1 ounces.
More importantly, it remained surprisingly resilient.
Instead of cracking like PLA when dropped, the foaming TPU absorbed impacts and immediately returned to its original shape.
For wearable cosplay pieces, that combination of low weight and durability is difficult to ignore.
Test Three: Bicycle Handle Grips
To compare the material against conventional TPU, we printed one of our existing bike handle grip designs.
This project highlighted one of the biggest differences between the two materials.
Traditional TPU feels like flexible rubber.
Foaming TPU feels much closer to the sole of a foam sandal or flip-flop.
It compresses more easily while still returning to its original shape.
Weight Comparison
|
Material |
Weight |
|---|---|
|
Standard TPU |
0.8 oz |
|
Foaming TPU |
Using identical geometry and infill, the foaming TPU version weighed exactly half as much.
Organic vs. Hard Surface Models
One of the more interesting discoveries involved print quality.
Organic models, like the Orc mask, produced slightly more stringing between fine features. This isn’t particularly surprising, as the material is actively expanding during printing.
Hard surface models, however, performed significantly better.
The Stormtrooper helmet showed noticeably cleaner surfaces with far less stringing than the organic model.
After adjusting print settings, stringing was reduced considerably across all projects.
As with any specialty material, dialing in the profile makes a substantial difference.
Temperature Changes More Than Print Quality
One of the unique characteristics of this material is that print temperature changes the properties of the finished part.
Printing hotter increases the foaming effect, resulting in:
- Lower weight
- Softer feel
- Greater expansion
- Lower material density
Printing at lower temperatures produces firmer parts with less expansion.
That gives makers an unusual level of control over the final properties of a print without changing materials.
Is It Better Than PLA?
Not necessarily.
PLA still produces sharper details and remains easier to finish with sanding and painting.
If you’re building a display piece that won’t be worn, PLA continues to be an excellent choice.
However, if you’re building helmets, masks, armor, creature suits, or other wearable props, weight quickly becomes one of the most important factors.
That’s where foaming TPU starts to shine.
After spending time printing with SainSmart’s Lightweight Foaming TPU Air, one thing became clear:
This isn’t simply “lighter TPU.”
It’s a completely different type of material with its own strengths.
The reduced weight, excellent impact resistance, and softer feel make it especially attractive for wearable cosplay projects where comfort matters just as much as appearance.
Will it replace PLA?
Probably not.
But it doesn’t need to.
Instead, it fills a gap between rigid plastics and conventional TPU that hasn’t really existed before.
If you’re building props you’ll actually wear—not just display—it’s absolutely a material worth experimenting with.
Materials Used
- SainSmart Lightweight Foaming TPU Air (95A Base TPU)
- Bambu Lab X1 Carbon
- PLA (comparison prints)
- Standard TPU (comparison prints)
“The best materials don’t just make better prints—they make better projects.”
— Bryan DeLuca, Maker Build It