Modular Foam Roller | Flexible

A full-size foam roller designed specifically for 3D printing.

This roller uses a rigid PLA core combined with a TPU outer shell to create a feel similar to commercial foam rollers while remaining printable on smaller machines through a segmented design. The assembled roller is strong, comfortable, and intended for general recovery, mobility work, stretching, and everyday use.

The surface texture varies around the roller, allowing for both smoother rolling areas and more aggressive sections depending on preference.

The modular construction also makes it possible to create large functional prints that normally would not fit within the build volume of many printers.

Features

• Full-size assembled foam roller
• TPU outer shell with rigid PLA core
• Segmented design for smaller printers
• No supports required
• Simple assembly
• Hidden seams during use
• Multiple texture intensities around the roller
• Designed to feel similar to commercial rollers

Dimensions

• Length: 350mm (13.8in)
• Diameter: 139.7mm (5.5in)

Print Information

Tested Materials

• SUNLU TPU 95A
• Bambu Lap TPU 95A HF
• SUNLU PLA+
• SUNLU PLA
• Bambu Lab PLA

Other materials may work but have not been tested.

Recommended Settings

PLA Core

• 0.28mm layer height
• 0.4mm nozzle
• 2 wall loops
• 5% gyroid infill

TPU Shell

• 0.28mm layer height
• 0.4mm nozzle
• 3 wall loops
• 3 top shell layers
• 5% gyroid infill

No supports are required.

TPU Printing Notes

If you are unfamiliar with TPU printing, drying your filament first is highly recommended. Printing TPU directly out of the box can lead to poor surface quality and inconsistent extrusion.

This model was designed around 95A TPU.

Assembly

The model consists of 5 printed parts:

• 2 TPU outer sections
• 2 PLA core sections
• 1 PLA locking screw

Assembly is straightforward and takes about a minute.

The TPU sections slide into channels in the core, and the printed screw locks everything together internally without requiring additional hardware.

The only important assembly detail is ensuring the TPU sections are inserted in the correct orientation so the surface pattern lines up properly.

Durability & Usage

The roller has been tested under normal use for about a month and performs similarly to commercial foam rollers.

The rigid core helps prevent collapsing under body weight while keeping the outer surface comfortable during use.

The roller is intended for indoor use. Because the core uses PLA, leaving it outside or in high temperatures for extended periods may deform the internal structure.

Future Plans

If there is enough interest, I may create:

• An A1 Mini compatible version
• Larger printer optimized versions
• Additional textures or firmness options

If you have ideas for future variants, feel free to leave a comment.