Phaetus aeWorthy™ PLA-AERO 1kg Spool

Lightweight active-foaming PLA — half the weight, matte finish

Phaetus aeWorthy PLA-AERO is a foaming PLA: as the nozzle gets hotter, the filament expands and the printed part gets lighter and less dense. You tune the foaming by temperature, so you can dial parts from denser/stronger at the low end to very light at the high end — up to roughly 200% expansion and about half the weight of standard PLA at the same volume. The surface comes out matte, which hides layer lines and takes paint and primer well. Built for RC wings and planes, drones, ship and aircraft models, large display pieces, and cosplay where weight, not load-bearing strength, is the goal.

Print settings (Phaetus)

• Diameter: 1.75 mm  |  Spool: 1 kg
• Nozzle: 200-240C — this is your foaming control. Lower = denser and stronger, higher = lighter and more foamed. Run a temperature tower to find your weight/strength sweet spot.
• Bed: 40-60C on glass, PC, or PEI film
• Print speed: 30-90 mm/s
• Part-cooling fan: ON

Two things that make or break foaming PLA

• Dry it first. Foaming PLA is humidity-sensitive — damp filament foams unevenly and leaves a rough, blistered surface. Dry around 55C for 6-8 hours before printing, and again after the spool has been sitting. A filament dryer or dry box is strongly recommended for consistent results.
• Reduce your flow / tune extrusion multiplier. Because the material expands in the nozzle, most slicers over-extrude with foaming PLA out of the box. Drop flow (commonly to ~50-60% at the high-temp/high-foam end) and re-tune per temperature. This is normal for the foaming-PLA class, not a defect.

Hardware

This is unfilled PLA — no glass or carbon fiber — so a standard brass nozzle is fine; no hardened or DLC nozzle required. If you want maximum foaming throughput on large wings, a larger-diameter nozzle (0.6-0.8 mm) gives the material more room to expand.

1 kg spool, 1.75 mm. Available in White, Grey, Red, and Yellow.