ADVANCED MATERIALS & PROCESSES | MAY 2026 56 3D PRINTSHOP LIGHTWEIGHT ‘SUPER FOAM’ ABSORBS ENERGY By combining a composite foam with 3D-printed injection “struts,” scientists have built an affordable, lightweight, and ultra-durable hybrid foam capable of absorbing up to 10 times more energy than conventional padding. The research team from Texas A&M University and the DEVCOM Army Research Laboratory (ARL) use a technique called in-foam additive manufacturing (IFAM). “IFAM is a simple, computer-driven manufacturing process that allows us to build an elastomeric skeleton inside of a conventional open- cell foam,” says Eric Wetzel, team leader for Strategic Polymers Additive Manufacturing at ARL. “The diameter, spacing, angle, and elasticity of the elastomer can be selected to achieve a wide range of properties.” During the early stages of compression, the foam acts like a brace, holding the struts steady so they don’t buckle too soon. As the pressure builds, the struts push the force outward into the surrounding foam, spreading the load. Together, this back-and-forth allows the composite to absorb more energy and withstand greater forces. The team is exploring how the hybrid foam could be transitioned into military helmets that are required to not only stop ballistic projectiles, but that must also provide a cushion during violent falls and collisions. tamu.edu. PRINTING ULTRAHARD CEMENTED CARBIDES A study published by researchers at Hiroshima University introduces a method of additively manufacturing defect-free, industrial- grade carbides. Tungsten carbide- cobalt (WC-Co) cemented carbides provide high wear resistance and hardness and are often used for cutting and construction tools. Research proposed in this study, published in the International Journal of Refractory Metals and Hard Materials focuses on the use of additive manufacturing (AM), specifically hot-wire laser irradiation along with two fabrication methods for their experiment. Hot-wire laser irradiation (also called laser hot-wire welding) is a technique in which a laser beam and a preheated filler wire are combined to increase the deposition rate (how much of the filler metal is added) and efficiency of the process. One of the fabrication methods used in this study involves direct irradiation on top of the cemented carbide rod, with the rod leading the direction of fabrication. The other method is led by the laser and is irradiated by the laser between the bottom of the cemented carbide rod and the base material (iron). In both methods, the metals are softened instead of completely melted to form the cemented carbide. “Cemented carbides are extremely hard materials used for cutting tool edges and similar applications, but they are made from very expensive raw materials such as tungsten and cobalt, making reduction of material usage highly desirable. By using AM, cemented carbide can be deposited only where it is needed, thereby reducing material consumption,” says corresponding author Keita Marumoto, assistant professor at Hiroshima University’s Graduate School of Advanced Science and Engineering. The results demonstrated this method to be effective in maintaining the hardness and mechanical integrity of conventionally manufactured WC-Co cemented carbides, achieving a base material with hardness of over 1400 HV (a unit representing resistance to penetration), without introducing any defects or decomposition. www.hiroshima-u.ac.jp/en. The foam and plastic struts team up under pressure, creating a hybrid material that can absorb up to 10 times more energy than standard padding. Courtesy of Abbey Toronjo/Texas A&M University Division of Marketing & Communications. Illustration of the laser leading method. Courtesy of Keita Marumoto, Hiroshima University.
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