MakerBot Print is our newest print-prepration software, which supports native CAD files and STL assemblies,
allows you to interact with all your printers via the Cloud, and many other exciting new features.
I have tried to do this before and the foam either was too strong and bowed the plastic or broke it entirely. I tried some other foam from smooth on and it ended up heating up too much that PLA delaminated or expanded. I agree there has got to be a good predictable way of doing this. I think plaster bandages may be an interesting way of temporarily reinforcing the print while the foam does its thing. I used an epoxy impregnated cloth (used to fix yard tool handles) to pretty good effect but it was a more permanent method.