Researchers Develop Ultra-Durable "Super Foam" Composite

Hybrid material combines ordinary foam with 3D-printed plastic struts for enhanced energy absorption and customizable properties.

Published on Mar. 7, 2026

Got story updates? Submit your updates here. ›

Aerospace engineering and materials science researchers at Texas A&M University and the DEVCOM Army Research Laboratory have developed a "super foam" that can absorb up to 10 times more energy than conventional padding. The composite combines an ordinary foam with 3D-printed injections of stretchy, plastic columns known as struts, resulting in an affordable, lightweight and ultra-durable hybrid foam poised to redefine the defense, automotive, aerospace and consumer industries.

Why it matters

This new hybrid foam material has the potential to provide significantly enhanced protection and safety in a wide range of applications, from military helmets and vehicle interiors to consumer products like sports gear and furniture. By combining the benefits of ordinary foam and engineered cellular structures, the researchers have created a customizable, high-performance composite that can be tuned for strength, energy absorption, comfort, or all three.

The details

The research team, led by Dr. Mohammad Naraghi from Texas A&M and Dr. Eric Wetzel from the Army Research Laboratory, developed a manufacturing process called In-Foam Additive Manufacturing (IFAM) that allows them to build an elastomeric skeleton inside of a conventional open-cell foam. By varying the thickness and angles of the 3D-printed plastic struts, the researchers can tune the properties of the hybrid foam to achieve the desired balance of protection, comfort, and weight.

  • The research was published in the journal Composite Structures on March 7, 2026.

The players

Dr. Mohammad Naraghi

Director of the Nanostructured Materials Lab at the Texas A&M College of Engineering and the lead researcher on the project.

Dr. Eric Wetzel

Team leader for Strategic Polymers Additive Manufacturing at the DEVCOM Army Research Laboratory and a collaborator on the project.

Texas A&M University

The university where the research was conducted, through the College of Engineering.

DEVCOM Army Research Laboratory

The U.S. Army's research and development center that sponsored the project and collaborated with Texas A&M.

Got photos? Submit your photos here. ›

What they’re saying

“We've turned a simple foam into a tunable, high-performance, super foam composite. It has the potential to be a universal solution for a wide range of applications.”

— Dr. Mohammad Naraghi, Director, Nanostructured Materials Lab, Texas A&M University (Mirage News)

“IFAM is a simple, computer-driven manufacturing process that allows us to build an elastomeric skeleton inside of a conventional open-cell foam. The diameter, spacing, angle and elasticity of the elastomer can be selected to achieve a wide range of properties. The IFAM process combines the best of both worlds, providing a low cost, customizable, high performance composite energy absorber.”

— Dr. Eric Wetzel, Team Leader, Strategic Polymers Additive Manufacturing, DEVCOM Army Research Laboratory (Mirage News)

What’s next

The research team is exploring how the hybrid foam could be transitioned into military helmets and other protective gear, as well as potential applications in passenger safety, vehicle design, and noise control.

The takeaway

This new hybrid foam material represents a significant advancement in energy-absorbing materials, combining the benefits of ordinary foam and engineered cellular structures to create a customizable, high-performance composite that could redefine safety standards and comfort across a wide range of industries.