Bead foam manufacturing technology is another foam processing technology route that is widely being used to manufacture low-density three-dimensional complex foam geometries. This chapter discusses a novel manufacturing technology to develop polylactide (PLA) bead foams via developing foams with double crystal melting peak and more specifically incorporating high-melting temperature crystals, generated during the saturation, in developing microcellular bead foams with high expansion ratios via influencing the cell nucleation and growth behavior of PLA bead foams. The low-melting peak crystals generated during the foaming/cooling further influence the foaming behavior of PLA. In this context, variations of PLA-CO2 mixtures' crystallization mechanisms could profoundly influence the foaming behavior of PLA. Steam-chest molding is further utilized to verify the interbead sintering behavior of the foamed beads.