RETHINKING PLASTICS: SMART FOAMS FOR LIGHTWEIGHT, CIRCULAR DESIGN
In an era where sustainability and performance are paramount, Foam Additive Manufacturing (FAM) is redefining the possibilities of plastic materials. Developed by the innovative Italian startup Oniro Srl, this groundbreaking 3D printing technology offers a new way to create advanced, single- material components with embedded foam, designed to meet the demands of diverse industries. By enabling precise control over the internal structure of each part, FAM unlocks a wealth of design possibilities that improve product performance, reduce weight, and enhance recyclability, all while simplifying manufacturing processes. From aerospace to food production, FAM is setting the stage for a future where material innovation drives both sustainability and efficiency.
In a world that demands lighter, stronger, and more sustainable products, Foam Additive Manufacturing (FAM) is changing how we think about plastic.
Developed by the Italian deep-tech startup Oniro Srl, this patented 3D printing technology enables the creation of advanced components made from a single recyclable material—with foam
inside. But these are not ordinary foams. With FAM, designers can control the internal structure of a part voxel by voxel, assigning different densities, stiffnesses, or energy absorption properties to each zone. This unlocks an entirely new design space for tailored monomaterial structures—components made from a single recyclable polymer, yet exhibiting locally optimized performance: helmets with integrated shock-absorbing cores, lightweight drone panels with tuned vibration damping, or packaging that protects sensitive electronics without excess bulk.
The key? No adhesives, no assembly, no multi- material layers.
Just one material, printed in a single pass—with different properties in different places. That means simpler recycling, lower weight, and faster production.
Impact across industries: lightweight, efficient, and sustainable solutions Across industries, the impact is already visible:
•Aerospace: Lightweight sandwich panels with programmed stiffness reduce weight by over 40%, with improved impact and vibration performance.
•Mobility & Sports: Bike saddles, shoe soles, or prosthetics that combine comfort and strength in one seamless piece.
•Design & Fashion: Furniture and accessories made from bio-based foams that are light, strong, and sustainable.
•Naval Architecture: Large-scale 3D printing of lightweight, impact-resistant structures enables rapid prototyping of interior components, hull elements, and buoyant systems—reducing production times and simplifying logistics for shipbuilding and marine applications.
Because everything is designed digitally, engineers and designers can experiment freely—without molds or tooling. The same material can behave like foam, rubber, or solid plastic, depending on how it’s printed. That means fast iteration, minimal waste, and full control over performance.
Scalable innovation and smart materials
Oniro is already collaborating with leading research institutions like the University of Naples Federico II, Massachusetts Institute of Technology, University of Milan, Aalto University, and the Institute for Computational Design and Construction at the University of Stuttgart—developing applications from aerospace to large-scale manufacturing.
Its vision: to bring programmable, monomaterial foams to market at scale— starting with large-format printers and smart porosity design software. With Foam Additive Manufacturing, plastic becomes more than just a shell. It becomes a performance material, tuned for circularity, lightness, and intelligence—shaped not just by form, but by function.
For more information please visit:
www.oniro.tech
info@oniro.tech
