Foam Metal
for the Final
Frontier
ITAR-registered foam metal materials for defense procurement, commercial space supply chains, satellite thermal management, space server shielding, and micrometeorite impact protection — engineered to perform where failure is not an option.
Three Functions.
One Integrated Material System.
Defense and space programs demand materials that perform multiple functions simultaneously. PrometheanFoam's foam metal architecture addresses EMI shielding, thermal management, and impact damping within a single integrated material layer — reducing mass, complexity, and failure points.
Electromagnetic Shielding & Directed Energy Protection
90–120 dB shielding effectiveness across 10 MHz–40 GHz, attenuating radar interference, communications jamming, EMP threats, and directed energy (HPM/microwave) weapon effects through reflection, absorption, and scattering.
- 90–120 dB SE · 10 MHz–40 GHz (MIL-STD-461G)
- MIL-DTL-83528 gasket performance
- EMP hardening per MIL-STD-461G CS115/CS116
- Directed energy per RS103 test method
- −65°C to +300°C operation
Space Server & Satellite Thermal Management
In the vacuum of space, convective cooling is impossible. PrometheanFoam nickel foam (>200 W/m·K) and copper foam (15–25 W/m·K) provide conductive and radiative thermal pathways for satellite bus electronics, in-orbit server racks, power electronics, and computing payloads. ASTM E595 outgassing certified — no vacuum contamination of optical or sensor systems.
- Nickel foam: >200 W/m·K conductivity
- Copper foam: 15–25 W/m·K + 90–110 dB EMI dual function
- ASTM E595: TML <1.0%, CVCM <0.1%
- 85–98% porosity for flow-through thermal paths
- LEO/MEO/GEO/deep space qualified
- New Space & commercial constellation programs
Micrometeorite & Orbital Debris Impact Damping
Open-cell metal foam absorbs hypervelocity impact energy through progressive cell collapse across the 3D porous matrix — distributing impact stress from micrometeorites, orbital debris (MMOD), and launch shock events. Functions as a lightweight, thermally stable bumper shield layer in composite protection systems.
- Progressive energy absorption via cell collapse
- Effective for 0.1–10 mm particle range
- 50% lighter than equivalent solid metal bumper
- −65°C to +300°C — no cold brittleness
- Launch vibration & acoustic damping (MIL-STD-810G)
- Compatible with Whipple shield composite systems
All three functions — EMI shielding, thermal management, and impact damping — can be integrated into a single custom-engineered foam metal assembly, reducing spacecraft mass, part count, and integration complexity. Contact our engineering team for multi-function design consultation.
Space-Grade Material Qualification
From LEO satellite constellations to deep space exploration, PrometheanFoam materials meet the demanding qualification requirements of commercial and government space programs.
Space Server & Edge Computing Thermal & EMI
The growing deployment of in-orbit computing — onboard AI inference, satellite edge servers, and real-time data processing payloads — creates unprecedented thermal and EMI challenges. In vacuum, heat can only be transferred by conduction and radiation. PrometheanFoam's open-cell metal foam provides the high-surface-area conductive network that moves heat from processors to radiator panels, while simultaneously shielding sensitive electronics from interference.
Our copper foam enables dual-function integration: a single 0.5–2 mm layer that simultaneously provides 90–110 dB EMI isolation between compute modules and 15–25 W/m·K lateral thermal spreading — eliminating the mass penalty of separate shielding and thermal interface layers.
MMOD Protection & Launch Vibration Damping
Micrometeorite and Orbital Debris (MMOD) threats are a primary risk factor for spacecraft longevity. Open-cell metal foam provides an engineered sacrificial layer that absorbs hypervelocity impact energy through progressive cell-wall deformation — analogous to Whipple bumper shield principles but in a thinner, lighter, thermally stable form.
During launch, the same material attenuates acoustic-induced vibration and mechanical shock events (MIL-STD-810G / ECSS-E-ST-10-03), protecting sensitive electronics and precision instruments from the 150+ dB acoustic environments of launch vehicles.
PrometheanFoam supports New Space program qualification timelines with rapid prototyping, fast material characterization, and agile documentation packages. Rapid prototyping available for constellation satellite programs, launch vehicle manufacturers, and in-orbit infrastructure operators. Contact sales@prometheanfoam.com or (307) 533-4550.
U.S. Military & Allied Defense Programs
Full compliance stack for DoD direct contracts, prime contractor supply chains, and NATO allied programs — ITAR, DFARS, MIL-SPEC, and AS9100 certified.
Military Standards Compliance Matrix
| Standard / Regulation | Full Description | Compliance Status | Primary Application |
|---|---|---|---|
| MIL-STD-461G | Electromagnetic Interference Control | ✓ Fully Compliant | All EMI shielding products |
| MIL-DTL-83528 | EMI/RFI Conductive Elastomeric Gaskets | ✓ Fully Compliant | Aircraft, ground systems |
| MIL-STD-810G | Environmental Engineering (vibration, shock, temp) | ✓ Tested to Spec | All military equipment |
| ITAR | International Traffic in Arms Regulations | ✓ Registered | All defense programs |
| DFARS | Defense Federal Acquisition Reg. Supplement | ✓ Compliant | DoD procurement |
| AS9100 Rev D | Aerospace Quality Management Standards | ✓ Certified Standards | All aerospace products |
| ASTM E595 | Outgassing in Vacuum — Space Applications | ✓ Certified | Satellite, spacecraft |
| MIL-PRF-31032 | Printed Board Assembly Materials | ✓ Material Qualified | Avionics, electronics |
| NATO STANAG | Allied Standardization Agreements | ✓ Compliant | International defense |
| DEF STAN 59-411 | UK EMC Defense Standard | ✓ Documentation Available | UK/Commonwealth programs |
Full MIL-SPEC compliance documentation, ITAR compliance certificates, AS9100 audit reports, and program-specific Technical Data Packages (TDP) are available to qualified defense contractors and prime vendors under executed NDA. Contact (307) 533-4550 or sales@prometheanfoam.com.
How Foam Metal Absorbs High-Energy Impacts
From hypervelocity micrometeorites in orbit to launch shock events and battlefield blast concussion, open-cell metal foam's architecture delivers progressive energy absorption that rigid materials cannot match.
Progressive Cell Collapse Model
When a high-velocity particle or blast wave strikes foam metal, energy is absorbed through a four-stage mechanism that spreads impact forces across millions of individual cell walls — rather than transmitting peak stress to the protected structure.
Proven in Critical Environments
Military Aircraft
EMI shielding for avionics, radar domes, EW/ECM equipment, and communications on fighter jets, transport aircraft, and rotary-wing platforms. MIL-DTL-83528 gaskets, −65°C to +300°C rated.
View Case Study →Satellites & Spacecraft
Thermal control, EMI payload protection, MMOD bumper shielding, and launch vibration damping for LEO/GEO satellites and deep space probes. ASTM E595 outgassing certified for all space environments.
View Case Study →Launch Vehicles & Rockets
Acoustic and vibration isolation for avionics bays and payload interfaces during ascent. Shock damping for stage separation and fairing jettison events. Lightweight — critical for every kg to orbit.
Naval Vessels
Marine-grade EMI shielding for shipboard radar, sonar, weapons control, and navigation systems. Salt-fog resistant alloy formulations. Navy TEMPEST program materials available under NDA.
View Case Study →In-Orbit Server Racks
Thermal spreading foam and EMI inter-module shielding for onboard AI inference engines, edge compute nodes, and in-orbit data processing platforms. No convection in vacuum — conduction is everything.
Ground Defense Systems
EMI protection for mobile command centers, field communications, portable radar, and EW systems. Blast and fragment impact damping for vehicle-mounted electronics. Ruggedized for field environments.
View Case Study →Explore the Full Portfolio
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