Texas A&M and US Army Develop Super Foam With 3D Printed Struts That Absorbs 10X More Energy

A Hybrid Approach to Impact Protection

Researchers at Texas A&M University and the DEVCOM Army Research Laboratory have developed a hybrid "super foam" that can absorb up to ten times more energy than conventional padding. The material combines standard open-cell foam with 3D-printed elastomeric struts injected directly into the foam's internal structure.

The approach turns a common, inexpensive material into a tunable composite designed to withstand significantly higher forces while remaining lightweight. The research could improve protective gear for soldiers, vehicle safety systems, and everyday products like cushions and helmets.

In-Foam Additive Manufacturing (IFAM)

The team developed a technique called In-Foam Additive Manufacturing (IFAM), which builds a network of elastic plastic struts directly inside open-cell foam using computer-controlled 3D printing.

IFAM is a simple, computer-driven manufacturing process that allows us to build an elastomeric skeleton inside of a conventional open-cell foam, said Dr. Eric Wetzel from the Army Research Laboratory.

By adjusting the diameter, spacing, and angles of the struts, researchers can tune the material's mechanical properties. During early compression, the foam stabilizes the struts and prevents them from buckling too quickly. As pressure increases, the struts distribute the force into the surrounding foam, spreading the load.

Military and Commercial Applications

Energy-absorbing materials are critical to a wide range of Army applications, including ballistic helmets and blast-resistant seat cushions, Wetzel explained. The hybrid foam could significantly improve protection in helmets used by soldiers while adding little weight.

Beyond defense applications, the same concept could be adapted for commercial helmets used in cycling, motorcycling, and sports. Researchers are also exploring its use in vehicle interiors and bumpers to help absorb collision forces.

The study was published in the journal Composite Structures.