New 'super foam' absorbs 10× more energy using 3D-printed skeleton

Researchers at Texas A&M University and the DEVCOM Army Research Laboratory have created a hybrid "super foam" that absorbs up to 10 times more energy than conventional foam padding. This innovative material integrates ordinary open-cell foam with a 3D-printed internal skeleton of flexible plastic struts, produced via a process called In-Foam Additive Manufacturing (IFAM). The embedded lattice structure reinforces the foam, allowing it to better distribute and absorb impact forces while remaining lightweight. By tuning the diameter, spacing, and angles of the struts, the mechanical properties of the composite can be customized for different applications. The development aims to enhance protective gear, particularly military helmets, by providing superior impact absorption without adding significant weight, thereby improving soldier comfort and mobility. Beyond defense, the hybrid foam has potential uses in commercial helmets, vehicle interiors, bumpers, and consumer products like mattresses and cushions, where zones of firmness and comfort can be tailored. Researchers are also investigating its ability to absorb sound and vibrations,