In-depth look at eSUN PEBA-LW, an ultra-lightweight foam filament with a density of only 0.48 g/cm³, offering up to 60% rebound and adjustable hardness from 66A-92A by varying print temperature. Ideal for sports shoe soles, wearables, and shock absorption applications.

The flexible 3D printing filament industry is seeing an exciting new option emerge as eSUN introduces PEBA-LW (Lightweight PEBA). This filament utilizes a physical microsphere foaming process, causing the material to "expand" during printing, resulting in lightweight, bouncy, and highly shock-absorbent parts compared to typical flexible filaments. The most outstanding feature is that users can adjust the hardness of the printed part from 66A to 92A simply by changing the nozzle temperature, without needing to switch filaments.

What is PEBA-LW?

PEBA-LW is a lightweight grade of PEBA (Polyether Block Amide) filament that undergoes physical foaming during printing. The material can expand in volume by up to 200% as the nozzle temperature increases. As it foams more, the hardness of the part decreases accordingly, allowing users to "design the softness-hardness" of their prints with fine detail using a single filament, unlike conventional flexible filaments where hardness is fixed by the manufacturer.

Key Features of eSUN PEBA-LW

1. Foamable and Adjustable Hardness (66A–92A)

With the microsphere foaming process, users can adjust the nozzle temperature from 215–240°C to control the foaming rate and the hardness of the part within a range of 66A (soft) to 92A (harder) using a single material. This is ideal for applications requiring multiple levels of hardness in the same part, such as shoe soles that need soft zones and weight-bearing zones in one design.

2. Excellent Bounce and Shock Absorption (Up to 60% Rebound)

PEBA-LW offers a high resilience/rebound rate of up to 60% at a print density of 30%, significantly outperforming common TPU-LW filaments. This makes it highly suitable for parts that need to absorb repeated impacts, such as sports shoe midsoles, seat cushions, or various damping components.

3. Ultra-Lightweight with Low Density

When fully foamed, the density of PEBA-LW reduces to just 0.48 g/cm³, which is approximately 15% lighter than PLA-LW and 52.5% lighter than PEBA-90A (non-foaming grade) at the same volume. This is ideal for applications where weight is a critical factor, such as footwear, wearables, and sports equipment.

4. Durable, Highly Flexible, and Resistant to Repeated Bending

Despite being lightweight and soft, PEBA-LW maintains excellent resistance to tearing and repeated bending without breaking. This makes it suitable for wearable devices that require constant movement or orthotic devices that demand high flexibility and fatigue resistance.

Key Specifications of eSUN PEBA-LW

• Brand: eSUN
• Diameter: 1.75 mm
• Net Weight: 0.8 KG/Roll
• Density: Less than 1.24 g/cm³ (can foam up to 0.48 g/cm³)
• Melt Flow Index: 5–15 g/10min (190°C/2.16kg)
• Tensile Strength (XY): 14 MPa
• Elongation at Break (XY): 500%
• Recommended Nozzle Temperature: 210–270°C
• Bed Temperature: 35–75°C
• Fan Speed: 100%

What Applications Is It Suitable For?

With its lightweight, bouncy, and adjustable hardness properties, PEBA-LW is suitable for a wide range of applications:

• Footwear Midsoles: Offers excellent shock absorption comparable to high-quality EVA foam.
• Wearable Devices: Lightweight, flexible, and comfortable.
• Rehabilitation Aids: Allows for localized hardness adjustment according to user needs.
• Industrial Shock Absorption & Sealing.

Conclusion

eSUN PEBA-LW is a new generation of flexible filament that combines foaming technology with the ability to adjust hardness via printing temperature. This makes it a comprehensive premium flexible material – lightweight, bouncy, and durable – ideal for those looking to develop projects in footwear, wearables, or shock-absorbing components.

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3D Printing eSUN Flexible Filament Foaming Filament PEBA-LW

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