Nickel Foam 45 PPI Fuel Cell Electrode Substrate ATOMFAIR®

NICKEL FOAM 45 PPI KNITTED 3D RETICULATED FUEL CELL ELECTRODE SUBSTRATE

RESEARCH GRADE MATERIAL

Product Overview

This next-generation Nickel Foam is engineered as a sponge-like porous metal material featuring a 45 PPI knitted 3D reticulated architecture manufactured through a specialized deposition process. With a specific gravity of merely 0.2–0.3—approximately one-quarter that of water and one-thirtieth that of iron—the hollow interconnected nickel skeleton achieves a bulk density of only 1/50th that of solid nickel while preserving the full spectrum of nickel’s intrinsic physicochemical properties. The fully open-cell structure delivers an exceptionally high specific surface area, making it an optimal fuel cell electrode substrate for Ni-H₂, Ni-Cd, and proton exchange membrane systems, as well as a nickel foam-carbon composite electrode platform for advanced lithium-ion energy storage. Exhibiting broadband acoustic absorption, high thermal conductivity, and robust acid-alkali corrosion resistant performance, this knitted metallic foam supports stable gas-liquid mass transfer and can be readily cut, bent, and bonded for integration into complex electrochemical, catalytic, and thermal management assemblies.

Technical Specifications

PARAMETER	DETAILS
Material	High-Purity Nickel (Ni)
Weaving Method	Knitted
Structure	Sponge-Like 3D Fully Interconnected Reticulated
Pore Density (PPI)	5–130 PPI (±5–10; Standard: 45 PPI)
Specific Gravity	0.2–0.3
Bulk Density	1/50th of Solid Nickel
Areal Density	280–3000 g/m² (±30–200)
Thickness Range	0.5–80 mm (±0.05–1.0)
Length / Width Range	70 mm ≤ L/W ≤ 500 mm (±0.5)
Corrosion Resistance	Acid & Alkali Resistant
Thermal Conductivity	High (Suitable for Heat Pipe Wick Applications)
Acoustic Performance	Broadband Sound Absorption
Processability	Cuttab le, Bendable, Bondable
Gas-Liquid Permeability	Stable Flow Characteristics
Alternative Options	Explore our related catalog or custom dimensions. For urgent technical custom requests or bulk inquiries, please contact our support team.

Key Features & Advantages

Ultra-Lightweight Hollow Skeleton Architecture: The knitted nickel skeleton achieves a specific gravity of 0.2–0.3 with bulk density merely 1/50th that of solid nickel. The hollow interconnected strut morphology maximizes specific surface area while minimizing mass, delivering an exceptional strength-to-weight ratio for portable energy storage and aerospace functional material applications.
Sponge-Like 3D Fully Interconnected Porosity: The specialized deposition process creates a true sponge-like reticulated structure with 100% open-cell connectivity, ensuring stable gas-liquid mass transfer and uniform fluid distribution across the entire substrate volume—critical for electrochemical reactions and catalytic processes where dead zones compromise efficiency.
Broadband Acoustic Absorption Capability: The stochastic 45 PPI knitted pore network effectively dissipates acoustic energy across a wide frequency spectrum through viscous friction and thermal conduction mechanisms within the micro-pores, enabling simultaneous noise reduction and structural functionality in integrated multifunctional designs.
Versatile Post-Processing Compatibility: The ductile nickel substrate can be readily cut, bent, and bonded without fracturing the interconnected strut network, facilitating custom shaping into complex geometries for application-specific electrochemical reactor, heat exchanger, and EMI shielding enclosure configurations.

APPLICATION SCOPE: Validated as a high-performance electrode substrate in Ni-H₂, Ni-Cd, and fuel cell systems, with nickel foam-carbon composite configurations optimized for lithium-ion batteries deployed in consumer electronics, electric vehicles, and power tools. Functions as a catalyst carrier and oil-water/oil-gas separation medium in chemical engineering processes, including automotive exhaust purification and air purification systems. Supports electrolytic hydrogen production, electrocatalysis, and electrochemical metallurgy in energy engineering applications. Serves as a thermal management material and heat pipe wick core for enhanced heat exchange efficiency. Applicable as a multifunctional material for acoustic absorption, vibration damping, electromagnetic shielding, stealth technology, flame retardancy, and thermal insulation in defense and industrial sectors.

PACKAGING: Supplied in custom-cut sheet configurations within the dimensional range of 70 mm to 500 mm for both length and width (±0.5 mm tolerance). Thickness is selectable from 0.5 mm to 80 mm (±0.05–1.0 mm tolerance). Standard areal density ranges from 280 to 3000 g/m² (±30–200 g/m²). Pore density is available from 5 to 130 PPI (±5–10 PPI), with 45 PPI as the standard offering. Each sheet is vacuum-sealed in low-outgassing polyethylene film with rigid protective backing to preserve the delicate knitted 3D reticulated structure during transit. Custom dimensions and PPI specifications manufactured to order.

IMPORTANT NOTICE: When handling knitted nickel foam sheets with thickness below 1 mm, utilize vacuum pickup tools or flat-tipped tweezers to avoid localized plastic deformation of the hollow strut network. For electrochemical electrode applications, pre-conditioning of the nickel surface via cyclic voltammetry in the target electrolyte is recommended to establish a stable electrochemical interface prior to active material loading. The material retains nickel’s intrinsic hydrogen absorption characteristics—hydrogen uptake increases with decreasing strut diameter—necessitating appropriate safety protocols during hydrogen-rich electrochemical operations. While the nickel skeleton is inherently acid-alkali resistant, prolonged exposure to oxidizing acids at elevated temperatures may gradually dissolve the passivating surface oxide layer. For maximum shelf stability, store in a desiccated, temperature-controlled environment.

TAILORED SOLUTIONS FOR RESEARCH

Contact our engineering team for technical support or official quotations.

EMAIL: inquiry@atomfair.com

Manufacturer: Atomfair LLC

Brand: ATOMFAIR®

This nickel foam substrate requires careful handling to avoid mechanical damage to its hollow strut network. Storage in a desiccated, temperature-controlled environment is necessary to preserve shelf stability and prevent surface degradation.

Mechanical Handling: For sheets thinner than 1 mm, use vacuum pickup tools or flat-tipped tweezers to prevent localized plastic deformation of the hollow strut network.
Electrochemical Pre-conditioning: Prior to active material loading, pre-condition the nickel surface via cyclic voltammetry in the target electrolyte to establish a stable electrochemical interface.
Hydrogen Safety: Because nickel absorbs hydrogen and uptake increases with decreasing strut diameter, implement appropriate safety protocols during hydrogen-rich electrochemical operations.
Chemical Compatibility: While the nickel skeleton is acid-alkali resistant, avoid prolonged exposure to oxidizing acids at elevated temperatures as they may dissolve the passivating surface oxide layer.
Storage Conditions: Store the material in a desiccated, temperature-controlled environment to maintain maximum shelf stability.

HowTo

This procedure covers the safe handling and preparation of nickel foam for electrochemical electrode applications. Follow these steps to avoid mechanical damage and establish a stable electrochemical interface.

Required Equipment: Vacuum pickup tools, Flat-tipped tweezers, Sharp blade or scissors, Cyclic voltammetry equipment

Inspect and Cut
Inspect the nickel foam sheet for visible damage, then cut it to the required dimensions using a sharp blade or scissors.
Handle Thin Sheets
For sheets thinner than 1 mm, handle using vacuum pickup tools or flat-tipped tweezers to prevent plastic deformation of the hollow strut network.
Pre-condition Surface
For electrochemical electrode applications, pre-condition the nickel surface by performing cyclic voltammetry in the target electrolyte before active material loading.
Store Prepared Substrate
After pre-conditioning, store the prepared substrate in a desiccated, temperature-controlled environment until final assembly.

FAQ

How does the 45 PPI pore density affect gas-liquid mass transfer and electrochemical performance in fuel cell electrode substrates?

The 45 PPI knitted 3D reticulated structure provides a fully interconnected open-cell network with stable gas-liquid mass transfer characteristics, ensuring uniform fluid distribution across the substrate volume. This pore density standard (45 PPI ±5–10) balances specific surface area and permeability, critical for Ni-H₂, Ni-Cd, and PEM fuel cell electrodes where dead zones compromise efficiency. The source specifies that the 45 PPI standard is part of a 5–130 PPI range, with each sheet vacuum-sealed to preserve the delicate structure.

Can this nickel foam be used as a catalyst carrier in electrolytic hydrogen production, and what is its corrosion resistance in acidic environments?

Yes, the nickel foam is validated for electrolytic hydrogen production and electrocatalysis applications, functioning as a catalyst carrier and gas-liquid separation medium. The nickel skeleton is inherently acid-alkali resistant, but the source warns that prolonged exposure to oxidizing acids at elevated temperatures may gradually dissolve the passivating surface oxide layer. For electrochemical electrode applications, pre-conditioning via cyclic voltammetry in the target electrolyte is recommended to stabilize the interface before active material loading.

What handling precautions are required when cutting or bonding thin nickel foam sheets below 1 mm thickness?

For sheets below 1 mm thickness, the source specifies using vacuum pickup tools or flat-tipped tweezers to avoid localized plastic deformation of the hollow strut network. The material is cuttable, bendable, and bondable without fracturing the interconnected structure, but the delicate knitted 3D reticulated architecture requires careful handling. Storage in a desiccated, temperature-controlled environment is recommended for maximum shelf stability, and hydrogen uptake increases with decreasing strut diameter, necessitating safety protocols during hydrogen-rich electrochemical operations.

Assessment

This 45 PPI knitted 3D reticulated nickel foam offers an ultra-lightweight, fully interconnected porous architecture with a specific gravity of 0.2–0.3 and bulk density only 1/50th of solid nickel, providing high specific surface area and stable gas-liquid mass transfer for fuel cell electrode substrates. The material is cuttable, bendable, and bondable, but thin sheets require careful handling and electrochemical applications demand pre-conditioning to establish a stable interface.

Positive

Ultra-Lightweight High-Surface-Area Skeleton: Specific gravity of 0.2–0.3 with bulk density 1/50th of solid nickel maximizes specific surface area while minimizing mass, delivering an exceptional strength-to-weight ratio for portable energy storage and aerospace applications.
Fully Interconnected 3D Porosity: 100% open-cell connectivity ensures stable gas-liquid mass transfer and uniform fluid distribution across the entire substrate volume, critical for electrochemical reactions and catalytic processes where dead zones compromise efficiency.

Trade-offs

Delicate Thin-Sheet Handling: For thickness below 1 mm, vacuum pickup tools or flat-tipped tweezers are required to avoid localized plastic deformation of the hollow strut network, increasing handling complexity during integration.
Electrochemical Pre-conditioning Required: For electrode applications, pre-conditioning via cyclic voltammetry in the target electrolyte is recommended to establish a stable electrochemical interface prior to active material loading, adding a preparatory step.

Quality Standards & Performance Verification

Every advanced material, component, equipment, and instrument in our catalog is backed by rigorous testing. We maintain strict internal quality management frameworks and align with CE conformity metrics to deliver transparent, reproducible performance data via our public open-science repository.

To request raw batch performance data, submit formal vendor registration paperwork, or execute a fast-turnaround R&D manufacturing loop, contact us at inquiry@atomfair.com.

Shipping & Returns

Item is dispatched under the Atomfair Shipping & Delivery Framework (Free worldwide shipping on orders over $59 USD excl. heavy equipment). Return is governed by the Atomfair Return & Refund Policy (7-day technical return window).