The compression/explosion process used in this study is promising because it produces starch-based foam in 10 s. The compressive properties and density of the foam are comparable with that of commercial products with the exception that the foam fractures under excessive strain. The compression/explosion process has an advantage over traditional puffing or extrusion technology in that the product can be molded during formation. Further advances in mold design and the incorporation of fibers or fillers may help provide for improved mechanical properties, more uniformity and better surface quality.