Questions engineers actually ask.

A microcellular polyurea elastomer: a cast elastomer with fine cells running all the way through it. That makes it light like foam and tough like rubber. The material is covered by a granted patent, and Super Foam holds the exclusive license from San Diego State University.

It looks like foam and it replaces foam, but it behaves like an engineered elastomer. Commodity foam crushes on the first serious hit; our material absorbs the impact and recovers its shape, hit after hit. We recommend specifying it like an engineered part, not a sheet of padding.

Our standard formulation absorbed 71.7 kJ/m³ in a peer-reviewed San Diego State University study (Journal of Applied Polymer Science, 2020, doi.org/10.1002/app.48839). That is nearly twice the energy of a leading commercial impact-protection foam used in sports and motorcycle protective gear, at 12% lower weight. In our own testing it loses under 20% of its load-bearing capacity after seven impacts and recovers 98% of its volume after a 25 m/s projectile impact. These are baseline values; your part is tuned to your targets.

Yes. The material contains no PFAS (“forever chemicals”).

Direct flame does not ignite the material in our testing, and flame retardancy is one of the properties we can tune for. Final fire-safety qualification is always done against the standard your application requires.

It depends on the formulation, which is why we start with your operating range. Tell us the hottest and coldest conditions your hardware sees. One of our customers runs battery-box corners in extreme cold.

You set the targets and we tune four things to meet them: density; additives and how much of each (we have tested graphene for UV protection, stiffness and static dissipation, a biocide for mold and bacteria resistance, and a fire retardant); thickness; and geometry. We cast the material to your part and check it in FEA before any tooling.

No. Tell us what the part must survive (impact, heat, vibration, static, weight) and we turn those targets into a formulation.

A STEP file is best for the FEA simulation; an STL works for the 3D preview, and drawings or photos help too. Upload them (up to 20 MB each) on the Design tools page or with your part spec.

You do. You own the IP for your specific formulation-and-shape combination. Super Foam keeps only aggregate learnings that improve the platform for future customers.

Exclusivity for your field of use can be discussed as part of a development project. Ask us about it in your first conversation.

Upload an STL on the Design tools page and see your own part in our elastomer, in a few finishes. STEP files are accepted too; we preview those for you. It is a visual preview only: performance is confirmed in the FEA session and on your sample.

FEA stands for finite element analysis: a computer simulation of how your part responds to impact and load. Our design team runs your part through it under the drops, strikes and vibration it will face in the field, and walks you through the results and what to change before you order a sample. Simulation is an inexpensive way to test how the material will behave in environmental conditions it has not been tested in yet, which fits our mission: material and part development that hardware startups can afford.

We don’t send generic swatches, because every part is custom, and a swatch wouldn’t tell you how your part will perform. Your sample is your part, made to your formulation.

Once the simulation looks right, we cast a sample of your part on our own patent-pending automated machine, the same machine built to run your production orders.

It depends on the part’s size, complexity and tooling. We give you a timeline and quote after the FEA session, once we know exactly what we’re making.

In Riverside, California, on our own automated production line. We’re based in a HUBZone.

Yes, that’s why we built our own machine. The machine that makes your sample is built to run your production orders, so what you approve is what you receive at volume.

Yes. Super Foam Corp is registered in SAM.gov (CAGE 07Q57), is HUBZone-based, and has graduated from the NavalX Crucible program.

Impact testing has been carried out at San Diego State University. Formal third-party certification is done per application, against the standards your program requires, and we’ll always tell you which values are tested and which are estimates.

3D-printed foam keeps expanding as it leaves the nozzle, so it can’t hold tight dimensions. We cast inside a closed mold, so every part matches the tooling.

Start a part spec from your dashboard, or book a design review with the team directly.

Request our pitch deck and we’ll be in touch personally.