THE METAL AGNOSTIC SOLUTION
Foaming technology
Ultra-high surface area metallic foams engineered to suit your needs
The apheros process
Unlike conventional metal foam manufacturing, which relies on sacrificial templates and physical vapor deposition to build structure layer by layer, the apheros process takes its inspiration from food science and traditional metallurgy.
We start with a water-based slurry of metallic powder, introduce a controlled foaming step to create the open-pore architecture, cast the result into molds, and finish with a thermal treatment that locks in the final structure.
The approach is inherently scalable and avoids the cost and geometric constraints of template-based methods, which is precisely what gives our material its distinctive combination of high surface area, consistent pore morphology, and manufacturing flexibility.
Material properties
Our ultra-high surface area metal foams offer unparalleled heat transfer, mass transport, and catalytic activity. Their fully open and interconnected pore structure ensures optimal fluid flow and wetting.
Nickel foam
Porosity range 75-90%
Compared to conventionally produced metal foams, apheros foams inherently have a 1000x larger surface area while maintaining fully open pores for optimal mass transport. Their structure is engineered for increased capillary action, leading to efficient wetting, bubble nucleation and release - ideal for demanding applications.
Ultra-high surface area
Apheros patented metal foaming technology leads to surface areas thousands of times larger than for conventional metal foams. We produce high-porosity (75%-95%) metal foams with precisely adjustable pore densities (up to 350 PPI), providing large reaction surfaces in a compact, lightweight package. Surfaces can be engineered to optimize bubble suppression or provide ample nucleation sites.
Open porosity
The microstructure of apheros metal foams consists of large pores that are fully interconnected, leading to a hierarchical network of open cells. The structures allow for optimal fluid flow and mass transport.
High wettability
The hierarchical and open microstructure of apheros metal foams leads to highly efficient wetting. Capillary action quickly transports liquid to the interior of the metal foam, lending it excellent wicking properties. A high capillary limit ensures a broad applicability of the materials.
Drop-in replacement
With densities ranging from 0.9 to 2.2 g/cm³, our metal foams are ideal for applications demanding lightweight components. Moreover, their seamless integration into existing systems through standard processes like bonding, welding, and machining makes them a drop-in replacement for your systems.
Our versatile processes allow us to work with a wide range of materials, offering unparalleled flexibility in composition and foam structure. This materials agnostic approach empowers you to choose the optimal composition and structure for your specific application. From copper, iron, nickel to stainless steel and other alloys, we offer a diverse portfolio of lightweight, highly porous foams tailored to your needs.