Prusament PLA-LW (Lightweight) reduces part weight by up to 65% compared to standard PLA — not through material properties but through active foaming. The material contains additives that activate at printing temperatures, expanding the extruded polymer as it exits the nozzle. The result: parts with a closed-cell foam interior that weigh significantly less while maintaining their printed geometry.
The practical effect on spool economy is notable: one kilogram of PLA-LW prints 2–3× as many models as standard PLA by mass. For applications where weight matters more than structural density — RC aircraft, drone frames, cosplay props, buoyancy components — this is the material.
How the Foaming Works
The extrusion multiplier controls foam intensity. At the recommended 0.45 setting, the material foams consistently. Increasing temperature increases foam expansion: maximum effect occurs at 235°C with temperatures controllable between 215°C and 235°C. Do not exceed 250°C — above that threshold, material degradation and potentially harmful fumes become a risk.
Print settings that differ from standard PLA:
- Extrusion multiplier: 0.45 (not the standard 1.0)
- Print temperature: 230°C default, adjustable 215–235°C
- Bed temperature: 60°C
- Retractions: Disabled — retraction causes irregular foaming and stringing
- Nozzle: 0.4mm or 0.6mm brass
The foaming process causes increased ooze between moves, producing visible stringing that requires post-processing removal. This is expected behavior with the material, not a calibration failure.
Applications
RC aircraft and drones — the primary design use case. Wing ribs, fuselage sections, and structural components where every gram saved extends flight time or allows heavier payloads. The 65% weight reduction translates directly to range and performance improvements.
Cosplay and props — armor pieces, weapons, and costume components where wearers carry the finished print. A chest plate that would weigh 400g in standard PLA weighs ~140g in PLA-LW.
Thermal insulation — the closed-cell foam structure creates air pockets that insulate similarly to polystyrene. For enclosures, brackets, or housing components near heat sources, this is a useful property.
Floating objects — buoyancy comparable to polystyrene. Waterproof coatings required for long-term water exposure, but the base material floats.
Pricing and Availability
$56.99 USD / €59.90 EUR per kilogram spool. Five colors: Army Green, Chocolate Brown, Galaxy Black, Natural, and Coral Orange. Available through the Prusa Store.
This is Prusament’s fourth distinct PLA formulation covered on Stack Archive (joining High-Speed, PA11 natural, and Resin Model Plus), each targeting a specific application segment rather than general-purpose printing.
The So What
PLA-LW does one thing that no other consumer FDM filament does at this price point: actively foams during extrusion to produce lightweight structural parts. For the applications where this matters — primarily RC aircraft and weight-constrained props — the 65% reduction in part mass is transformative. The print settings are non-standard enough to warrant dedicated profiles, but the material is predictable once calibrated.
The $56.99 price point is reasonable given the specialty nature. The 2–3× spool efficiency also changes the economics: at equivalent part volume, PLA-LW costs less per cubic centimeter of printed geometry than its nominal price suggests.
Source: Prusa Blog
Content created with AI assistance and reviewed for accuracy.
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