Volatile species are removed from polymers by devolatilization. Foaming experiments using corn syrup and low-density polyethylene were carried out to investigate effects of volatile content operating vacuum level and stripping agent in devolatilization. When foaming and rupture occur, a limiting foam volume growth was observed for a polymer regardless of the volatile content and the addition of stripper bubbles. A mathematical model was also developed to study the effect of stripper bubbles in polymer devolatilization. Based on the cell model for bubble growth, a bimodal model for foam growth is developed as the first step to describe the initial formation and growth of the volatile and stripper bubbles in polymer during devolatilization. When foaming and breakup occur at a critical foam volume expansion, a film model for mass transfer is used to model the second step of devolatilization. A numerical factorial study shows that the devolatilization section should be designed and operated to provide the screw channel sufficient free volume and residence time for the desired foam expansion.