Nickel, Copper & Iron Foam
That Lasts.
Mass-produced open-cell nickel, copper, iron and nickel-iron foam in sheets, rolls and custom sizes for batteries, electrolysis, thermal management and EMI shielding. Plus permanent, washable metal foam for commercial kitchen filtration, PM2.5 air quality, HVAC humidity control, aluminum casting, fog water harvesting, and industrial air treatment. One material. Every application. Never replaced.
What Is Metal Foam?
Nickel, Copper & Iron Foam
Metal foam is a porous metal with a sponge-like, open-cell structure. Most of its volume is open space, connected by a three-dimensional network of thin metal struts. That gives a very large internal surface area at low weight and low pressure drop, which is why metal foam is used for filtration, heat transfer, battery and electrolysis electrodes, EMI shielding, flame arresting and sound absorption.
PrometheanFoam supplies nickel, copper, iron and nickel-iron foam from one of the largest non-aluminum metal foam production bases, with ISO 9001:2015 certified mass production. That means continuous sheets and rolls with consistent pore size and thickness, and guaranteed supply for production programs, not lab batches.
| Material | Key properties | Typical applications |
|---|---|---|
| Nickel foam | Corrosion resistant, electrically conductive, high porosity | Battery electrodes, supercapacitors, hydrogen water electrolysis, catalyst supports, EMI shielding |
| Copper foam | Highest thermal and electrical conductivity of the group | Heat sinks, heat exchangers, thermal management, battery current collectors |
| Iron foam | Lower cost, strong, magnetic | Aluminum casting filtration, structural and catalyst-support uses |
| Nickel-iron foam | Balance of cost, strength and corrosion resistance | Industrial dust and oil-mist capture, fog water collection, air filtration |
Sheets, rolls and custom die-cut shapes. Custom PPI, thickness from 0.3 mm, and custom alloys. Nickel & iron foam pricing · Copper foam pricing · Material specifications
Every Metal Foam Application,
One Manufacturer
Direct from our certified production partner. No distributors, no markup. All products use the same open-cell technology — customized per application.
Kitchen Hood Metal Foam Filter
PM2.5 Metal Foam Air Filter (Permanent)
PF-160 Industrial Dust, Mist & Fog Collector
Passive HVAC Humidity Control Filter
Air Purifier Replacement Filters (Metal Foam)
Iron Foam Aluminum Casting Filters
Nickel, Copper & Iron Foam — Sheets & Rolls
PF-160: The Industrial System That
Pays for Itself in 2–6 Months
3-in-1 dust, oil mist, and fog water recovery in one permanent system. Eliminates $8,000–$40,000/year in disposable filter costs. Recovers 100–200 L/hr of water from cooling tower exhaust.
120–180 Pa pressure drop · 10+ yr lifespan
2-year warranty · ISO 9001:2015
From $8,000/yr Consumable
Cost → Zero. Plus Water Recovery.
Facilities spending $8,000–$40,000/year on disposable filters and water makeup costs see 2–6 month payback periods. A copper mine in Chile's Atacama Desert recovers $26,000–$70,000/year in water savings alone.
Permanent vs Disposable —
The Engineering Case
Every PrometheanFoam product eliminates replacement cycles. The economics compound. The performance never degrades.
| Performance Factor | Disposable Filters | PrometheanFoam Metal Foam |
|---|---|---|
| Lifespan | 3–6 months (replace) | 10+ years (wash & reuse) |
| 5-Year Cost (per location) | $600–$3,200 | $159–$279 (one purchase) |
| Efficiency Over Time | Degrades — no warning | 100% restored after each wash |
| Heavy Pollution (Delhi AQI 300+) | Fails in 2–4 weeks | 4–6 week cleaning cycle, indefinite |
| Temperature Rating | HEPA: max 120°C · NFPA filter: 850°F | Metal foam: 600°C · Kitchen grade: 1650°F |
| Cleaning Time | Discard & replace | 5 minutes pressure wash |
| Landfill Waste | 100% to landfill | 100% recyclable metal |
Where Metal Foam Solves
Real Problems Right Now
Eight high-growth markets where PrometheanFoam products are deployed — or in high demand. Each driven by a different problem, all solved by the same technology.
Phoenix, Tucson, Las Vegas. Haboob dust storms generate PM10 spikes to 1,000–5,000 μg/m³. Evaporative coolers + metal foam = 92.4% capture. 300+ installs. Data center & residential demand surging.
Arizona PM2.5 Guide →Fastest-growing PM2.5 filtration market 2025–2030 (15% CAGR). Delhi AQI 8–12× WHO limits. Underground mines, hyperscale data centers, nuclear facilities eliminating $8,000–$40,000/yr filter replacement costs.
India PM2.5 Report →Red Sea coast: 60–80 fog days/year. Solar-powered Ni-Fe foam produces water at $1.05/m³ vs $4.20/m³ desalination. Vision 2030 aligned. SIDF 40–60% subsidy eligible. Yanbu Industrial City pilot recommended.
Saudi Arabia Fog Report →UAE Water Security Strategy 2036 targets non-conventional water sources. NYUAD research confirmed UAE as highest-priority AWH market. Kuwait desalination at $4.5–5.5/m³ — fastest ROI case in GCC.
GCC Water Report →Pilbara iron ore and gold mines pay premium water costs. PF-160 fog water recovery from cooling towers delivers $26,000–$70,000/yr savings. Perth and Queensland coastal industrial facilities also high-demand.
Cooling Tower Guide →Atacama Desert copper mines pay $3–8/m³ for freshwater trucked in. PF-160 fog collector 2–6 month payback. Codelco, BHP, and Antofagasta supply chain. 40-year fog harvesting history in this region.
PF-160 Industrial System →NFPA 96 compliance driving retrofit market. 1 million+ commercial kitchens in the US. Metal foam replaces baffle filters with 95% vs 70% grease capture. 4.9★ from 156 verified reviews. $16,100/yr avg customer savings.
Kitchen Engineering Study →California Title 24, NYC Local Law 97, ASHRAE 90.1 energy codes are driving low-pressure-drop filter retrofits. Data centers (West Coast, Texas, Southeast) are early adopters: 30% fan energy reduction in pilot deployments.
HEPA Alternative Guide →Trusted by Engineers
& Operations Teams
"Switched 48 restaurant filters to metal foam. $16,100 annual savings. Duct cleaning dropped from every 6 months to once a year. Zero fire incidents since installation."
"PrometheanFoam's 30 PPI nickel foam solved our BMS EMI interference. 30% weight reduction vs traditional materials. 3 weeks from sampling to full production run."
"ISO certified, on-time delivery, excellent technical support. Our go-to supplier for 3 years. Engineering team responds within hours. Material certifications always complete."
Latest from the
PrometheanFoam Lab
Peer-reviewed guides, field data, and global market analysis — from our engineering team.
Metal Foam vs HEPA: 40% Energy Savings, 600°C Rated, Fully Reusable
5 peer-reviewed citations. Pressure drop 100–300 Pa vs 250–500 Pa for HEPA. Data center, automotive, lab field data. ASHRAE 52.2 compliant.
New GuideCooling Tower Fog Harvesting: 500–2,000 Gallons/Day, 6 Peer-Reviewed Citations
Field data: Arizona 520 gal/day avg; CA coast 1,850 gal/day. $5,700–$130,000/yr savings. 2–4 year ROI. Stanford-verified data.
New GuideIndia PM2.5 Filters: Mines, Data Centers & Nuclear Facilities
Fastest-growing PM2.5 filtration market. Eliminates $8,000–$40,000/yr filter replacement. Zero consumables. Underground mine & nuclear grade.
Market ReportDesert Fog Harvesting: $1.05/m³ vs $4.20/m³ Desalination — GCC Technical Report
83% feasibility. 18–32 L/m²/day. Solar-powered Ni-Fe foam. Vision 2030 aligned. SIDF funding eligible. 5 peer-reviewed citations.
Technical ReportArizona Desert Dust: 92.4% PM2.5 Capture, Haboob Recovery in 15 Minutes
4 Google Scholar citations. Phoenix/Tucson 300+ installs. Data center 14-week cleaning intervals. $11,400/5yr savings. Evaporative cooler compatible.
Case StudyBaffle Filters vs Metal Foam: 95% vs 70% Grease Capture — Engineering Analysis
85% fire risk reduction. 3 case studies. ROI calculator. $1,200 annual savings per kitchen. NFPA 96 compliance guide with full CFD analysis.
From Specification to Production
in 4 Steps
Most customers reach production-ready orders within 3–6 weeks.
Test Before You
Commit
All sample kit fees are 100% credited toward production orders over $1,000.
- 3–4 standard material variants
- Basic technical data sheets
- Standard US shipping included
- Email technical support
- Ships within 2–3 business days
- Tailored to your exact specifications
- Pre-call technical consultation
- 5–6 custom material variants
- Detailed test report included
- Priority shipping + engineering contact
- Pre-selected for your industry
- Data center / EV / Aerospace grade
- Custom application testing
- Expedited global shipping
- Dedicated engineering contact