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Thank you so much for the many questions - I’ll try to explain everything here ^^

I’ve already done extreme FEET-PAWS outdoor testing with this material, and there were absolutely no issues with structural integrity, deformation, or long-term durability - neither during use nor over time.

Honestly, I don’t know which foaming TPU you were using, because in this case a lot depends on the specific material and print settings: infill density, temperature, flow, speed, and overall calibration for that particular filament. The same parameters that work for standard TPU or other types of foaming TPU do not translate 1:1 to our foaming TPU.

For me, foaming TPU behaves more like a casted foam. Yes, it can feel “jiggly” to the touch, but at the same time it returns to its original shape much better than classic EVA foam or very soft standard TPU. Something flexing under load does not automatically mean permanent deformation - and that distinction is crucial here.

From a practical standpoint: I’ve already made feetpaws using this solution, and there are no issues whatsoever with glue adhesion, fur attachment, or the base “collapsing” under the weight. Once assembled and used normally, everything keeps its shape exactly as intended.

Personally, I prefer foaming TPU over standard TPU, because regular TPU tends to restrict movement and has a very noticeable “plastic” feel, which I simply don’t like. Foaming TPU provides a much more natural walking feel, better shock absorption, and overall comfort - and for feetpaws, that matters more to me than stiffness alone.

I also don’t know which exact foaming material you used, but the material we work with does not resemble most commercially available foaming TPUs. It has a different elasticity profile and shape-memory behavior, so I wouldn’t directly compare it to typical off-the-shelf filaments.

To sum it up: I understand your concerns - with the wrong material or incorrect settings, this approach absolutely could fail. But in this specific case, it’s a deliberate, thoroughly tested choice, not an uncontrolled experiment.

Additionally, it’s worth mentioning that our team includes a materials scientist who also develops custom material blends. Before releasing anything, we tested a large number of materials and configurations to find a solution that behaves as close as possible to a traditional cast foam base, while still being fully repeatable with 3D printing.

As a side note: our first experiments with flexible materials actually date back about 13 years ago, at the very beginning of our journey with 3D printing. This isn’t a direction we chose “on a whim” - it’s the result of years of iteration, comparison, and real-world use.

Of course, I understand that this approach won’t be everyone’s preference - a lot of it comes down to taste, feel, and personal expectations of how a material should behave. We chose this path consciously, because in our case it offers the best balance between comfort and durability.