Additive Manufacturing 3D-Printed Structure Makes Foam More Stable

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Researchers at Texas A&M University have additively manufactured a superfoam that can absorb 10 times more energy than a conventional foam. This 3D-printed foam could have a significant impact in the defense sector and save lives.

In the conventional production of foams, the internal structure was problematic: either a random pattern is chosen, which limits energy absorption, or more technical materials and grid structures are chosen, which are more expensive and more difficult to mass-produce. The decision is therefore between precision and price.

Foam And 3D Printing: How Does It Work?

But that could change thanks to 3D printing. The team at Texas A&M University has developed a technique called "In-Foam Additive Manufacturing" (IFAM), which makes it possible to create a 3D network of plastic struts within a foam area. The combination of the two is used to better resist the applied compressive force. These plastic struts are inserted directly into the foam at the desired locations. This integrates the 3D-printed structure into the foam.

IFAM is a simple, computer-aided manufacturing process that enables us to construct an elastomer frame within a conventional foam with open cells.

Dr. Eric Wetzel

If you look at the functionality of the final block, the foam initially acts as a reinforcement. When the applied force acts on the structure, the struts come into play: they push this pressure outwards from the foam. The result? The structure can absorb more energy and therefore withstand heavier loads. Dr. Eric Wetzel, Team Leader for Strategic Polymer Additive Manufacturing at the Army Research Laboratory, explains: "IFAM is a simple, computer-aided manufacturing process that allows us to design an elastomeric frame inside a conventional open-cell foam. The diameter, spacing, angle and elasticity of the elastomer can be selected to achieve a wide range of properties. The IFAM process combines the best of both worlds and provides a customizable, high-performance and cost-effective energy-absorbing composite material."

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Applications of the Super Foam

As the project is funded by the military, it is not surprising that this super foam is being developed for defense applications. For example, it is used in military helmets or as an explosion-resistant seat cushion. It offers a lighter and more efficient material in terms of energy and shock absorption: an ideal solution for many military applications. This foam could reduce the risk of injury and potentially save lives.
And why not use it for more general applications? The researchers mention the possibility of integrating it into bicycle and motorcycle helmets or even sports equipment. It can also cover the bumpers of cars to better protect passengers from serious collisions. Beyond its ability to absorb energy, this hybrid foam could also dampen noise and reduce overall acoustics. Dr. Mohammad Naraghi, professor at Texas A&M University and leader of this study, explains: "It would be possible to modify the properties of the foam to make it an excellent acoustic absorber that attenuates or even completely eliminates certain frequency bands and specific vibrations. Acoustic applications are still in the early stages of research, but we would like to explore this property further to transform the foam into a more powerful active sound absorber than current materials." Finally, the team is interested in the customization possibilities offered by additive manufacturing: Why not design customized cushions that adapt to the person's needs and physiology? For example, a firmer zone for the neck, but a softer one for the legs.

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