September 29, 2026 · 3D Printing News
Prusa Research announced Prusament PLA Lightweight on September 17, adding an actively foaming filament to its materials range. The company says it can produce parts with up to 65% less weight than regular PLA, with applications including model aircraft and cosplay. That figure is a manufacturer claim, rather than a result we've independently measured. Read the official announcement.
What changes during printing?
According to Prusa, additives cause the material to expand when heated in the nozzle. The resulting parts have a matte, finely textured surface, and their colors become paler as foaming increases. The company also flags extra nozzle ooze and stringing, so its setup guidance matters.
Prusa recommends using the appropriate material profile and calibrating when experimenting with settings. Its announcement includes printer profiles and handling guidance. This is filament for extrusion printing; it isn't a resin for vat-based miniature printers.
What we'd look for in a hobby project
Our take: begin with the job the finished piece needs to do. For a costume component carried around all afternoon, we'd put weight near the top of the checklist. For a small display figure, we'd ask different questions: how does the surface look after painting, how well do the parts fit, and does the result hold up to the handling it will receive?
A useful trial would be one representative part from your own project. Compare its weight, finish, assembly fit, and cleanup effort with your usual material. That gives you a decision based on the thing you actually want to make.
We haven't tested this filament, and this announcement doesn't change the materials specified in PrintedByAliens product listings. It is an interesting option to investigate for projects where weight matters. Follow Prusa's current instructions for the technical details.
Featured image: Prusa Research's official Prusament PLA Lightweight announcement image, showing a model aircraft. Image and reporting source.