05/14/2026
By Danielle Fretwell

The Francis College of Engineering, Department of Plastics Engineering, invites you to attend a Master's Thesis defense by Nariman Rajabifar titled: "Development of ethylene-vinyl acetate foams using material extrusion additive manufacturing."

Candidate Name: Nariman Rajabifar
Degree: Master’s
Defense Date: Tuesday, May 19, 2026
Time: 11 a.m. - 1 p.m.
Location: Perry Hall 215

Committee:

  • Advisor: Amir Ameli, Ph.D., Associate Professor, Plastics Engineering, UMass Lowell
  • Jay H. Park, Ph.D., Associate Professor, Plastics Engineering, UMass Lowell
  • Akshay Kokil, Ph.D., Assistant Professor, Plastics Engineering, UMass Lowell

Brief Abstract:
This thesis examines leveraging material extrusion additive manufacturing (MEXAM) to create ethylene-vinyl acetate (EVA) foams engineered for potential diverse industrial uses. It opens with an overview of additive manufacturing and highlights why EVA foams, known for their elasticity, flexibility, and low density, are widely used across consumer and commercial products. The work then focuses on developing 3D printed EVA foams that incorporate expandable microspheres (EMs). Initial printing trials are conducted to evaluate print quality and determine the range of foam densities achievable under different processing conditions. By systematically adjusting variables such as flow rate and nozzle temperature, the study investigates how each factor affects foam density. These findings offer practical guidance for optimizing MEXAM processes for foam production. The thesis also evaluates the mechanical properties of 3D printed EVA foams with different densities. Through a detailed analysis of mechanical and physical properties, the research demonstrates that additive manufacturing can produce foam components with characteristics comparable to, or better than, those made through conventional methods. This capability opens new opportunities for design flexibility and manufacturing efficiency. The thermal investigation also revealed the role of EMs on the crystallization of 3D printed EVA foams. Overall, this work advances the understanding of how MEXAM can be applied to fabricate elastomeric foams, offering pathways to modernize foam manufacturing and enhance product performance, functionality, and customization across multiple applications.