In this study, we explore the use of solid-state nucleation in polymer pellets as a means to create microcellular PLA foams in extrusion. This is achieved by using gas-saturated PLA pellets as input to the extruder. Foam density, bubble size, and bubble density is reported and compared with microcellular foams created in the gas-injection extrusion process. PLA pellet gas concentrations between 17 and 29 mg CO2/g PLA was found to produce quality microcellular foams in this process. Gas concentrations within this range were achieved by varying methods that included partial saturation, desorption from full saturation, and blending saturated with unsaturated pellets. This gas concentration window that produced microcellular foams was found to be independent of the saturation and desorption process used to achieve the desired concentration. We further compare the pressure drop and pressure drop rate of the gas-saturated pellet extrusion process showing that similar foams can be produced at pressures orders of magnitude lower than the alternative gas-injection extrusion processes. Investigations into extrusion pressures support the hypothesis that the gas-saturated pellet extrusion process utilizes solid-state nucleation in the feed section of the extruder to achieve high bubble density foams. (c) 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 127: 1967-1973, 2013