Reticulated Metal Foam 30–140 PPI 98% Porous ATOMFAIR®

RETICULATED METAL FOAM 30-140 PPI 98% THROUGH-POROSITY ELECTRODE SUBSTRATE

RESEARCH GRADE MATERIAL

Product Overview

Engineered for advanced electrochemical and thermo-fluidic research, this Reticulated Metal Foam serves as a high-performance conductive porous media with exceptional structural homogeneity. The substrate achieves a 98% through-porosity 30-140 PPI rating, eliminating closed-cell barriers to ensure unimpeded fluid and gas permeation for filtration studies. The interconnected three-dimensional network provides a significantly enhanced specific surface area, making it an optimal electrode current collector substrate for next-generation Ni-Zn batteries and supercapacitors. With a precisely controlled pore density range spanning 30–140 PPI, pore sizes from 0.3 mm to 7 mm, bulk density of 0.1–2.0 g/cm³, and areal density of 100–2000 g/m², this foam facilitates uniform current distribution and catalytic loading. The surface is passivated against atmospheric oxidation and the product is vacuum-sealed passivated surface packaged between rigid protective plates, delivering reproducible results in demanding research and development environments.

Technical Specifications

PARAMETER	DETAILS
Pore Density (PPI)	30–140 PPI (Selectable)
Through-Hole Ratio	≥98%
Porosity	60%
Pore Size Range	0.3 mm–7 mm (Inverse of PPI)
Substrate Dimensions	500 × 500 × 10 mm (Custom Available)
Thickness Range	0.8 mm–10 mm
Areal Density	100–2000 g/m²
Bulk Density	0.1–2.0 g/cm³
Surface Treatment	Passivated Against Atmospheric Oxidation
Custom Configurations	Custom dimensions, pore densities, and bulk thickness specifications are available upon request. Please contact us via email for engineering inquiries and bulk orders.

Key Features & Advantages

Maximized Electrochemical Surface Area: The 3D reticulated structure provides a significantly larger specific surface area compared to flat substrates or traditional meshes, enhancing charge transfer kinetics in cyclic voltammetry and galvanostatic cycling measurements.
True Open-Cell Permeability: Guaranteeing ≥98% through-porosity, this conductive porous media eliminates stagnation zones, ensuring uniform fluid flow and mass transport in flow batteries and catalytic filtration reactors.
Broad-Frequency Acoustic Attenuation: The stochastic micro-pore geometry effectively traps and dissipates acoustic energy via viscous friction, providing superior noise reduction for high-frequency electronic component enclosures.
Hybrid Thermal-Mechanical Performance: Exhibiting excellent electrical conductivity alongside flame-arresting properties, the foam serves as a dual-purpose heat spreader and fire-retardant barrier for battery pack safety applications.

APPLICATION SCOPE: Validated for use as an electrode skeleton in Ni-Zn batteries and electric double-layer capacitors. Compatible as a high-surface-area catalyst carrier in fixed-bed reactors and as an electromagnetic interference shielding core in sensitive analytical instrumentation. Suitable for inert atmosphere liquid filtration and dynamic pressure dampening in relief valves.

PACKAGING: Supplied as a single monolithic sheet (500 × 500 mm). The surface is passivated against atmospheric oxidation. The product is vacuum-sealed within a low-outgassing polyethylene bag and placed between rigid protective plates to prevent mechanical deformation of the delicate micro-porous structure during transit.

IMPORTANT NOTICE: For extreme high-temperature electrochemical applications (T > 300°C), pre-treatment of the metal foam in a reducing atmosphere is recommended to remove surface oxides. To preserve the 98% through-hole structural integrity, manual handling must utilize vacuum pickup tools; lateral mechanical gripping may collapse edge pores. Store in a desiccator or glovebox immediately after unsealing to prevent moisture adsorption.

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 pore density (PPI) selection affect the trade-off between surface area and flow resistance in this reticulated metal foam for electrochemical applications?

Higher PPI values increase the specific surface area available for charge transfer and catalytic loading, but also reduce pore size, which can elevate fluid flow resistance. The 98% through-porosity and interconnected 3D network ensure that even at higher PPI (up to 140), stagnation zones are minimized, maintaining uniform mass transport for flow batteries and catalytic reactors. Pore size inversely scales with PPI across the 0.3 mm to 7 mm range, allowing researchers to balance surface area and permeability based on their specific electrochemical or thermo-fluidic requirements.

Is this reticulated metal foam directly usable in high-temperature electrochemical applications above 300°C?

No, for extreme high-temperature applications above 300°C, the foam requires pre-treatment in a reducing atmosphere to remove surface oxides that form during the passivation process. Below 300°C, the passivated surface is stable and compatible with Ni-Zn batteries, supercapacitors, and other electrochemical systems. The product is vacuum-sealed to preserve the passivated layer until use, but the reducing pre-treatment is essential for elevated-temperature operation.

What are the recommended handling and storage procedures to preserve the 98% through-porosity structure of this metal foam after unsealing?

To preserve the delicate micro-porous structure, manual handling must use vacuum pickup tools; lateral mechanical gripping can collapse edge pores. Immediately after unsealing the vacuum-sealed polyethylene bag, the foam should be stored in a desiccator or glovebox to prevent moisture adsorption. The passivated surface protects against atmospheric oxidation during storage, but care must be taken to avoid mechanical deformation, as the foam is supplied between rigid protective plates for transit.

Assessment

This reticulated metal foam substrate offers a 98% through-porosity and 30–140 PPI pore density range, providing high specific surface area for electrode and filtration applications, but requires vacuum pickup handling to avoid pore collapse and storage in a desiccator or glovebox after unsealing to prevent moisture adsorption.

Positive

High through-porosity for unimpeded flow: With ≥98% through-porosity, this foam eliminates closed-cell barriers, ensuring uniform fluid and gas permeation in flow batteries and catalytic filtration reactors.
Passivated surface for oxidation resistance: The surface is passivated against atmospheric oxidation and vacuum-sealed between rigid plates, preserving structural integrity and reproducibility in demanding research environments.

Trade-offs

Requires vacuum pickup handling: Manual handling must use vacuum pickup tools; lateral mechanical gripping may collapse edge pores, compromising the 98% through-hole structural integrity.
Post-unsealing moisture sensitivity: After unsealing, the foam must be stored in a desiccator or glovebox to prevent moisture adsorption, adding infrastructure requirements for routine use.

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).