3D-Printed Hybrid Foam Absorbs 10 Times More Energy

At Texas A&M University, researchers have created a superfoam using additive manufacturing. The composite is capable of absorbing up to 10 times more energy than conventional foam. This 3D-printed material could have a significant impact on the defense sector and potentially save lives.

One of the challenges associated with the conventional manufacturing of these foams lies in their internal structure. Manufacturers must typically choose between a random pattern, which limits energy absorption, or more technical materials and lattice structures that are more expensive and difficult to produce at scale. In other words, it is often a trade-off between precision and cost.

The team places 3D-printed struts inside the foam.

Foam and 3D Printing: How Does It Work?

But this could change thanks to 3D printing. The team has developed a technique called In-Foam Additive Manufacturing (IFAM) that enables the creation of a 3D network of plastic struts within a block of foam. Combining the two materials allows the structure to better withstand applied pressure. These plastic struts are placed exactly where needed, directly inside the foam. In this way, the 3D-printed structure becomes integrated into the foam.