Metal foams are metals with an open, sponge-like structure. Instead of a solid sheet, the metal forms a continuous three-dimensional network of thin struts surrounding interconnected pores. That structure gives a large surface area, low weight and an electrically and thermally conductive skeleton that liquids and gases can flow through.
What is nickel foam?
Nickel foam is the most widely used open-cell metal foam. It is typically produced by coating a polyurethane foam template with nickel, then removing the polymer by heat treatment and sintering the remaining metal network. The finished sheet keeps the shape of the original foam but consists of hollow nickel struts with very high porosity.
How metal foams are specified
- Material and purity – nickel, copper, aluminium, stainless steel and others.
- PPI (pores per inch) – the number of pores along one inch; a higher PPI means smaller pores.
- Porosity – the share of the volume that is empty space.
- Thickness and sheet size – usually given in millimetres.
- Areal or bulk density – the amount of metal per unit area or volume.
Where metal foams are used
| Foam | Common uses |
|---|---|
| Nickel foam | Current collectors and electrode substrates for nickel-based batteries and supercapacitors; supports for electrocatalysts in water splitting; filters |
| Copper foam | Heat exchangers and heat sinks; current collector research for lithium batteries; catalyst supports |
| Aluminium foam | Lightweight structures, energy absorption, sound damping, heat exchange |
| Stainless steel foam | Filtration and corrosion-resistant porous structures |
| Reticulated vitreous carbon (RVC) foam | Porous electrodes for electrochemistry; high-temperature and chemically inert applications |
Handling tips
- Cut foam with sharp scissors or a blade and avoid crushing the pore structure.
- For electrochemical work, the surface is usually cleaned before use to remove oxide and residues; follow the procedure given in your method.
- Store foams dry and in their packaging to limit surface oxidation.
See the metal foams range for Electrical Conductive Nickel Metal Foam, Copper Foam and RVC foam, or metal foils if you need a solid current collector instead.
Frequently asked questions
What does PPI mean for metal foam?
PPI means pores per inch. It describes pore size: the higher the PPI, the finer the foam.
Why is nickel foam used in batteries and supercapacitors?
Its conductive three-dimensional network carries current through the whole electrode and its open pores hold active material and let electrolyte reach it.
Is nickel foam the same as nickel mesh?
No. Mesh is a woven or expanded two-dimensional sheet, while foam is a three-dimensional porous network with much higher surface area per unit volume.
How do I get metal foam price in India?
Send the material, PPI, thickness, sheet size and quantity through our contact page and Chemazone India will quote.