Scientists map foams for maximum energy absorption and safety

Mechanical engineers at the University of Wisconsin–Madison have developed a novel design framework that significantly streamlines the creation of shock-absorbing foam materials used in protective gear and aerospace applications. Unlike traditional foam design, which focused mainly on maintaining a constant stress plateau and optimizing mechanical properties alone, this new approach simultaneously considers foam thickness, surface area, and mechanical behavior. The researchers found that foams exhibiting nonlinear stress-strain responses can outperform conventional “ideal absorber” foams, especially in compact designs, expanding the design possibilities for energy-absorbing materials. The framework generates a design map based on inputs such as foam thickness, area, and material properties, enabling engineers to customize foams for maximum energy absorption with minimal weight and volume. Demonstrated on vertically aligned carbon nanotube foams, the method allows rapid optimization without extensive trial and error. Freely available online, the framework has broad applicability across various material systems, including metamaterials and soft robotics, and could revolutionize the development of lighter, safer