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

Researchers at Texas A&M University, in partnership with the US Army Research Laboratory, have developed a groundbreaking superfoam that uses 3D-printed plastic struts embedded within conventional foam to dramatically improve energy absorption.

The Problem with Traditional Foam

Conventional foam manufacturing forces engineers to make a difficult trade-off: random foam patterns are cheap but limit energy absorption, while technical lattice structures offer better performance but are expensive and difficult to produce at scale.

Enter IFAM: In-Foam Additive Manufacturing

The team created a technique called In-Foam Additive Manufacturing (IFAM) that embeds a 3D network of plastic struts directly inside a block of foam. These precisely-placed struts work with the foam to redirect pressure outward when force is applied, allowing the composite structure to absorb significantly more energy.

IFAM is a simple, computer-aided manufacturing process that allows us to build an elastomeric skeleton within conventional open-cell foam, explained Dr. Eric Wetzel, team leader for strategic polymer additive manufacturing at the Army Research Laboratory.

Defense and Civilian Applications

Funded by the military, this superfoam was developed with defense applications in mind — think military helmets, blast-resistant seat cushions, and battlefield protective equipment. However, the researchers see broader potential in bicycle and motorcycle helmets, automotive safety, acoustic damping, and custom comfort products.