New bio-based graphene foams can be used to build aerospace objects

Researchers in the EU project Bio.3DGREEN, coordinated by Laser Zentrum Hannover e.V., have developed bio-based graphene foams using renewable raw materials as sustainable alternatives to conventional lightweight and damping materials for automotive, aerospace, and marine applications. Inspired by natural porous structures like spongy bone and plant tissues, these graphene foams are engineered into three-dimensional networks that combine low density with high mechanical resilience. They can absorb mechanical shocks efficiently and maintain structural integrity after repeated stress cycles, outperforming traditional foams in durability and energy dissipation. A key innovation is the use of bio-derived precursors instead of fossil-based chemicals, reducing environmental impact and supporting sustainable manufacturing. The project also pioneers the use of these foams in additive manufacturing, overcoming challenges such as developing a specialized feeding system for the paste made from coated metal particles and plant oil, and optimizing laser wavelengths for precise processing. As fabrication techniques improve and environmental concerns grow, bio-based graphene foams are poised to transition from laboratory research to commercial use