How to 3dprint foam TPU + tips for cosplay application

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  • Create Date 20/02/2025
  • Last Updated 05/10/2026

How to 3dprint foam TPU + tips for cosplay application

Slicer presets for Varioshore TPU and other active foam TPU.
Types of active foam TPU:
Colorfabb Varioshore TPU (smoothest results, but highest price per kg, smaller roll than normal)
SirayaTech TPU Air 85: slightly grainy texture, better price value per kg, lower flowrates possible, full kg rolls
SirayaTech TPU Air 95: Same finish as TPU air 85, but harder filament. Feeds easier, doesnt get stuck as easily, allows faster print speeds and more complex designs. Printed parts feel less flexible than other foaming tpu.
Esun TPU-LW (similar to sirayatech, smaller roll than normal)

Remember that foam prints at close to half of the flowrate of a regular TPU print. So the price value per kg of completed parts is only half of that of regular (TPU) filament, even though the initial price per spool may look high. You'll be able to print 2 spools worth of parts per 1 spool of active foaming filament.

This is a zip file as the file format is not supported by my website, you need to extract it first before importing the model. Use winzip or 7zip to do that.
Drop the 3mf file into the slicer or load in the bbscfg for bambu studio.
Change the selected machine and nozzle size to your own.
The exact process and filament settings can differ per machine or filament brand. Print the sphere test model then adjust the temperature, flow rate and print speed of the filament until your machine has a decent result. Make sure your filament path pulls easily and is directly feeding into the extruder gear.

Read more tips and tricks here.