Researchers atTexas A&M Universityand theDEVCOM Army Research Laboratoryhave engineered a composite that absorbs up to ten times more energy than conventional padding, threading a 3D printed elastomeric skeleton through ordinary open-cell foam to deliver a material that is affordable and lightweight without sacrificing durability or performance.
The implications stretch well beyond protective gear, standing to reshape defense, automotive, aerospace, and consumer industries wherever energy absorption, weight reduction, and scalable production converge.
Published in the journalComposite Structures, the research was led by Dr. Mohammad Naraghi, director of the Nanostructured Materials Lab at Texas A&M’s College of Engineering, in collaboration with Dr. Eric Wetzel, team leader for Strategic Polymers Additive Manufacturing at ARL.
How the Two Materials Work Together
The manufacturing process behind the composite is called In-Foam Additive Manufacturing, or IFAM. Rather than fabricating a separate structure and combining it with foam afterward, IFAM deposits a network of stretchy plastic struts directly inside an existing foam block. The geometry of those struts, including their diameter, angular orientation, and spacing, can be adjusted through computer-controlled parameters to target specific mechanical outcomes.
The physical interaction between the two materials is what makes the composite perform beyond the sum of its parts. During the initial phase of compression, the surrounding foam constrains the struts, preventing them from buckling prematurely. As pressure intensifies, the struts redirect force laterally into the adjacent foam, distributing stress across a wider area. This reciprocal load-sharing continues as compression deepens, enabling the composite to sustain higher forces for longer.
“The IFAM process combines the best of both worlds, providing a low cost, customizable, high performance composite energy absorber,” said Wetzel.
From Military Helmets to Passenger Seats
“Head and brain injuries remain a significant concern for the U.S. Army, and any material innovation that allows us to provide greater protection, while also managing comfort and keeping weights low, is a valuable step forward,” Wetzel said. “Furthermore, the IFAM process is easily transferrable to scaled, real-world manufacturing.”
The same material translates directly to civilian use. Bicycle, motorcycle, and sports helmets, car bumpers, door panels, and child safety seats are all on the team’s radar, applying the same energy-trapping principle to impacts on roads and highways.
Source: 3D Printing Industry
