There are some fabrication limitations due to the foam’s structure, but in general, it can be fabricated similar to conventional solid materials.

The primary limitations are part thickness and feature control, which vary with the pore size of the foam. For a foam with large pores, the part needs to be thick enough to hold its structure together. The same concept applies to fine part features, such as sharp edges, small holes, precise angles, etc.

As a general rule of thumb, below is a table of suggested minimum thicknesses for carbon and ceramic foams. Metal foams generally follow these same thickness limitations, but we can compress the structure to achieve a thinner panel, as needed.

Please contact us to discuss the manufacturability of your design concepts.

Nominal Pore Size Grade Suggested Minimum Sheet Thickness
1001/16
801/16
601/8
451/8
303/16
201/4
101/2
53/4