Hybrid Foam Absorbs Up to Ten Times More Energy

A novel manufacturing process creates an elastic plastic network within a foam. The composite material is intended for use in protective systems, vehicles, and other applications in the future.

A research team from Texas A&M University and the DEVCOM Army Research Laboratory has developed a novel foam composite that can absorb significantly more energy than conventional cushioning materials. The material combines an open-cell foam with an internal network of elastic plastic struts. The findings were published in the journal Composite Structures.

According to the study, the hybrid material can absorb up to ten times more energy than conventional padding. The basis for this is a process called In-Foam Additive Manufacturing (IFAM), in which an elastic plastic framework is incorporated directly into the foam using additive manufacturing. The resulting structures form a three-dimensional network whose properties can be precisely adjusted using parameters such as diameter, spacing, angle, or elasticity.

Structured Collaboration Within the Material

The composite’s high energy absorption is due to the fact that the foam and plastic struts work together under load. In an early loading phase, the foam stabilizes the structures to prevent premature buckling. As compression increases, the struts transfer forces to the surrounding areas. This distributes the load and increases the mechanical load-bearing capacity.

Potential for Military and Civilian Applications

The project is part of a military research grant. According to the information provided, energy-absorbing materials play a central role in applications such as ballistic helmets and seat cushions in military vehicles. The new composite is said to be lightweight, adaptable, and capable of enhancing the protective performance of existing systems without significantly increasing weight.

Civilian applications are also being investigated. Potential uses range from protective helmets in sports and transportation to crash-relevant vehicle structures and seat padding. In addition, the researchers are examining the extent to which the material can be used for acoustic damping. The internal structure of the hybrid foam could thus be adapted to specifically dampen certain frequencies and vibrations.

This is a partly automated translation of this german article.