Nickel Foam 45 PPI 3D 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®

How does the 45 PPI knitted 3D reticulated architecture of this nickel foam affect gas-liquid mass transfer efficiency compared to lower-PPI foams for fuel cell electrode substrates?

The 45 PPI knitted 3D reticulated structure provides a fully interconnected open-cell network that ensures stable gas-liquid mass transfer and uniform fluid distribution across the entire substrate volume, critical for electrochemical reactions where dead zones compromise efficiency. The source specifies a pore density range of 5–130 PPI with ±5–10 tolerance, and the standard 45 PPI offering balances high specific surface area with adequate permeability for Ni-H₂, Ni-Cd, and PEM fuel cell systems.

Can this nickel foam be integrated directly as a current collector in lithium-ion battery electrodes without additional surface treatment?

The nickel foam is validated as a nickel foam-carbon composite electrode platform for advanced lithium-ion energy storage, but the source recommends pre-conditioning via cyclic voltammetry in the target electrolyte to establish a stable electrochemical interface prior to active material loading. The material retains nickel's intrinsic hydrogen absorption characteristics, which may require consideration during cell assembly, and the ductile substrate can be cut, bent, and bonded for custom electrode geometries.

What handling precautions are required to prevent mechanical damage to the hollow nickel strut network during electrode fabrication?

For sheets below 1 mm thickness, vacuum pickup tools or flat-tipped tweezers must be used to avoid localized plastic deformation of the hollow strut network. The material has a bulk density of only 1/50th that of solid nickel and a specific gravity of 0.2–0.3, making it mechanically delicate despite preserving nickel's intrinsic properties. The source also notes that prolonged exposure to oxidizing acids at elevated temperatures may dissolve the passivating surface oxide layer, and storage in a desiccated, temperature-controlled environment is recommended for maximum shelf stability.

Assessment

This variable-product nickel foam (45 PPI knitted reticulated) offers an ultra-lightweight hollow skeleton with fully interconnected porosity ideal for fuel cell electrode substrates and catalytic applications; however thin sheets require careful handling to avoid strut deformation and prolonged exposure to oxidizing acids at elevated temperatures can compromise corrosion resistance.

Positive

Ultra-lightweight high surface area architecture: Specific gravity of 0.2–0.3 and bulk density only 1/50th that of solid nickel maximize specific surface area while minimizing mass for portable energy storage and aerospace applications.
Fully interconnected open-cell porosity: 100% open-cell connectivity ensures stable gas-liquid mass transfer and uniform fluid distribution across the substrate volume critical for electrochemical reactions without dead zones.

Trade-offs

Handling sensitivity for thin sheets: Sheets below 1 mm thickness require vacuum pickup tools or flat-tipped tweezers to avoid localized plastic deformation of the hollow strut network.
Environmental corrosion limitations: Prolonged exposure to oxidizing acids at elevated temperatures may gradually dissolve the passivating surface oxide layer; storage requires desiccated temperature-controlled environment.

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).