01
Battery Protection
In a car crash, our single-piece battery tray acts as an active crumple zone, dissipating impact energy before it reaches the battery and critical electronics.
Material science
The Super Foam Matrix
A patented microcellular polyurea elastomer engineered for one job: convert kinetic energy into heat and recover its own geometry, impact after impact, without a single PFAS compound.
- 71.7 kJ/m³
- Energy absorption
- 98 %
- Volumetric recovery
- <20 % loss
- Load-bearing loss
- -12 % mass
- Weight reduction
Nearly 2x traditional foams
From 25 m/s projectile impact
Measured after 7 impacts
While +30% stiffer
Demonstration
Watch it take a hit
A drone body made with Super Foam absorbs the impact, bounces back and keeps flying.
Drone body · Super Foam
Video
Multi-impact behaviour
Built to take a hit. Then six more.
Commodity foams are single-use by physics: the first serious impact crushes the cell structure permanently, and every impact after that lands on a material that is already spent. The Super Foam Matrix holds its load-bearing capacity within 20% across seven impacts, and returns 98% of its original volume after a 25 m/s projectile strike.
That turns impact protection from a consumable into a reusable structural layer.
Load-bearing retention floor
≥80%
100%
80%
60%
40%
20%
0%
≤20% loss budget
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03
04
05
06
07
Impact sequence
Bars indicate the guaranteed retention floor across the 7-impact test sequence (<20% total load-bearing loss), not individual per-impact measurements.
Comparative matrix
Line by line against traditional foams
Five metrics that decide whether a protective layer survives its second impact, and whether it survives its next regulatory review.
71.7
kJ/m³
Energy Dissipation
100
% PFAS-free
Chemical Profile
+30
% stiffer
Weight-to-Volume Ratio
98
% recovery
Multi-Impact Recovery
0
tariffs
Supply Chain Origin
Energy Dissipation
- Traditional foams
- Degrading over multi-impact
- Super Foam Matrix
- <20% load-bearing loss after 7 impacts
- The advantage
- Nearly 2x energy absorption (71.7 kJ/m³)
Chemical Profile
- Traditional foams
- Contains trace PFAS / Toxins
- Super Foam Matrix
- 100% PFAS-Free / Eco-Pure
- The advantage
- Regulatory Proof
Weight-to-Volume Ratio
- Traditional foams
- Variable / Unpredictable
- Super Foam Matrix
- -12% lighter, +30% stiffer
- The advantage
- Optimizes Payload / Speed
Multi-Impact Recovery
- Traditional foams
- Permanent deformation after impact
- Super Foam Matrix
- 98% volumetric recovery from 25 m/s projectile impact
- The advantage
- Reusable protection, not single-use
Supply Chain Origin
- Traditional foams
- High overseas reliance
- Super Foam Matrix
- Fully Automated, U.S. Made
- The advantage
- Zero Tariffs, Minimal Lead Time
Figures reflect internal test results for the patented Super Foam polyurea matrix. Full methodology available under NDA.
BBattery protection
Replace three materials with one
Battery pack assembly is where the matrix collapses an entire bill of materials into a single ultra-lightweight insert.
02
Replace three materials with one
Today, battery pack assemblers must combine liquid potting, rigid mica shields, and heavy metal structures to handle fire risks and impact. We replace that entire complex assembly with a single, ultra-lightweight polyurea insert saving weight and assembly time.
03
Direct flame and voltage
Direct flame does not ignite the elastomer and variations can dissipate differing levels of voltage.
Formulation
Patented material. Patent-pending production.
The core polyurea material is covered by a granted patent. It was developed at San Diego State University, and Super Foam holds the exclusive license to commercialize it.
We make it on an automated production machine of our own design. That machine’s patent application is filed and pending.
P-01
Patented material, exclusive license
A granted patent covers the polyurea formulation. Super Foam holds the exclusive license from San Diego State University.
P-02
100% PFAS-free, Eco-Pure
No trace PFAS, no forever chemicals, no regulatory exposure that tightens every year.
P-03
Automated, U.S. made · patent pending
Our own automated production machine removes hand-finishing variance, tariffs and long lead times. Its patent application is pending.
Evaluation
Test it against your threat model.
Send us the load case, the temperature range, or the pack geometry. We will tell you whether the matrix is the right layer, and show you the data behind the answer.