Using his background in business development, chemical engineering, and software development, and drawing on his time at MIT's Laboratory for Aviation and the Environment focusing on renewal jet fuels, Matthew Pearlson realized that the aviation industry's best chance at environmental success was not to change the fuel source, but rather to light weight the entire industry. With this as his motivation, Pearlson began to look at modifying the stereolithography (SLA) process to print with foam.
Pearlson tested the concept for the Foam Printing Project over a holiday vacation in Phoenix. Requesting various resin samples by overnight mail days before the New Year, Pearlson awoke one morning and tested his concept in his father-in-law's garage to validate he could foam and cure several formulations with the Arizona sun.
Once he proved the underlying technology, Pearlson began to perfect it on an industrial desktop SLA machine. With assistance through MIT's Beaverworks and the MIT Sandbox Innovation fund, he began printing components for the aviation industry that were lighter and cheaper than traditional methods.
Pearlson has filed a utility patent which is currently pending before the Patent and Trademark Office.