Phaetus aeWorthy™ ASA-AERO 1kg

Phaetus aeWorthy ASA-AERO — Lightweight Foaming ASA, 1.75mm, 1kg

ASA-AERO is a foaming ASA: a chemical blowing agent sits dormant in the filament and activates in the hotend, so you tune print weight straight from the nozzle temperature. Run it hotter and the material foams more and prints lighter — Phaetus rates up to a 250% foaming ratio, which can bring a finished part down to roughly 40-50% of the weight of the same part in standard ASA. It keeps ASA's UV-aging and heat resistance, so parts hold up outdoors.

It's built for weight-critical work: RC aircraft and foamies, ship models, drone parts, and anywhere you want stiffness-per-gram without going to foam board. The foamed surface comes out matte, which softens the look of layer lines.

What it prints like

• Set weight with temperature. Nozzle 240-280C — lower end = denser/stronger, higher end = lighter/more foam. Dial it in on a test part before committing a build.
• Turn retraction OFF. The filament keeps expanding inside the nozzle, so stringing during travels is inherent and retraction tuning won't clear it. Phaetus recommends disabling retraction and cleaning up travels in slicer instead.
• Use an enclosure. Like all ASA, it wants a warm ambient (roughly 40-70C) to release internal stress and stop warping. Bed 80-110C on glass, PEI, or PVP glue stick.
• Nozzle size. >=0.4mm works; go >=0.6mm for thin single-wall models so foamed walls keep their strength.
• Ventilate. ASA outgasses — run it in a ventilated room.

Hardware

No hardened nozzle needed. ASA-AERO is foamed chemically, not filled with glass or carbon fiber, so it is not abrasive — a standard brass or plated-copper nozzle is fine. (Don't confuse it with the fiber-filled aeWorthy line — ASA-GF and ABS-GF are abrasive and do need a hardened/wear-resistant nozzle.)

Keep it dry

ASA is hygroscopic and a foaming filament is especially fussy about moisture — wet filament foams inconsistently and can bubble or string worse. Dry before use (around 80C for ~8 hours is typical for ASA-Aero; Phaetus's TDS doesn't publish an exact schedule) and print from a dry box if you can. A filament dryer is the right pairing here.

Spec: 1.75mm, 1kg net, Natural. Base filament density 1.03 g/cm3. Nozzle 240-280C, bed 80-110C, enclosure recommended, retraction off, brass nozzle OK.