Metal Foam Market Size and Outlook 2031

Report Description

Forecast Period	2027-2031
Market Size (2025)	USD 102.84 Million
CAGR (2026-2031)	5.36%
Fastest Growing Segment	Automotive
Largest Market	Asia Pacific
Market Size (2031)	USD 140.67 Million

Market Overview

The Global Metal Foam Market will grow from USD 102.84 Million in 2025 to USD 140.67 Million by 2031 at a 5.36% CAGR. Metal foam is a cellular structure composed of a solid metal matrix containing a large volume of gas-filled pores, offering a unique combination of high stiffness, low density, and superior energy absorption. The market is primarily supported by the escalating demand for lightweighting solutions in the automotive and aerospace sectors to enhance fuel efficiency and payload capacity. Furthermore, the material is increasingly utilised for thermal management and crash protection systems within the rapidly expanding electric vehicle industry. This sector benefits from a robust raw material supply chain; according to the International Aluminium Institute, in 2024, global primary aluminium production reached approximately 72.8 million tonnes, ensuring consistent feedstock availability for aluminium foam fabrication.

One significant challenge impeding the broader expansion of the Global Metal Foam Market is the high cost associated with manufacturing processes. Achieving consistent pore uniformity requires advanced and expensive production techniques, which often results in price points that limit the material's commercial viability in cost-sensitive industrial applications compared to traditional lightweight composites.

Key Market Drivers

The surge in electric vehicle (EV) adoption necessitates weight reduction, acting as a primary catalyst for the metal foam market as manufacturers seek to offset heavy battery masses without compromising structural integrity. Metal foams are increasingly integrated into battery housings and crash boxes due to their exceptional stiffness-to-weight ratio and kinetic energy absorption capabilities, directly addressing the industry's focus on range extension and safety. While the broader automotive sector remains vast—according to the European Automobile Manufacturers’ Association, May 2024, in its economic market report, global motor vehicle production reached 93.5 million units in 2023—the specific pivot toward electrification is driving the adoption of these advanced composites over traditional steel. This trend is quantified by the rapid expansion of the electric fleet; according to the International Energy Agency, April 2024, in the 'Global EV Outlook 2024', sales of electric cars reached nearly 14 million in 2023, creating a substantial and growing application base for lightweight cellular metals.

Growing utilization in aerospace for structural efficiency serves as the second significant driver, propelled by the industry's imperativeness to minimize fuel consumption and maximize payload through advanced materials. Metal foam cores are utilized in sandwich panels for bulkheads and floorings to provide superior vibration damping and thermal insulation compared to polymer counterparts. This sector is currently experiencing a strong manufacturing resurgence which secures high-value demand for metal foam components. According to Airbus, January 2024, in its 'Full-Year 2023 Deliveries' update, the company delivered 735 commercial aircraft in 2023, indicating a robust recovery in production rates that directly correlates with increased procurement of high-performance, lightweight structural solutions.

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Key Market Challenges

The high manufacturing cost associated with producing metal foams stands as a critical barrier impeding the broader expansion of the market. Achieving the necessary pore uniformity and structural integrity requires complex, energy-intensive fabrication techniques, such as direct foaming or powder metallurgy, which significantly elevate the final price of the material. This cost premium limits the commercial viability of metal foams in price-sensitive sectors like mass-market automotive production and general construction, where manufacturers often opt for less expensive traditional alternatives despite the superior performance characteristics of foam.

These economic pressures are exacerbated by the volatile energy costs required to process the raw metal matrix, which directly impacts the scalability of foam production. The industry's reliance on energy-intensive smelting and foaming processes makes it highly vulnerable to fluctuations in industrial power rates. According to European Aluminium, in 2024, primary aluminium production in Western and Central Europe decreased to approximately 2.83 million tonnes, a decline attributed largely to high energy prices and resulting capacity curtailments. This strain on the cost structure of the base material processing underscores the financial challenges facing the metal foam sector, effectively stifling its potential for rapid growth in high-volume applications.

Key Market Trends

The development of porous titanium foam for orthopedic implants constitutes a major market trend, driven by the material's ability to closely mimic the structural and biological properties of natural bone. Unlike solid titanium, this porous structure facilitates osseointegration, allowing bone tissue to grow directly into the implant's cellular matrix, which enhances stability and significantly reduces the risk of stress shielding. This shift towards biologically optimized materials is fueling growth within the reconstructive sector. According to Stryker, January 2024, in its '2023 Operating Results', net sales in the Orthopaedics and Spine segment increased by 10.5% to reach $8.7 billion for the full year 2023, underscoring the robust commercial demand for advanced implant technologies utilizing such porous metal architectures.

Concurrently, the application of metal foams for electromagnetic interference (EMI) shielding is expanding rapidly to support the densification of global 5G infrastructure. As telecommunication networks migrate to higher frequency bands, the need for lightweight materials that can effectively absorb rather than just reflect electromagnetic waves becomes critical to maintaining signal integrity across closely packed base stations. This requirement for superior shielding solutions is directly propelled by the aggressive deployment of next-generation mobile networks. According to Ericsson, June 2024, in the 'Ericsson Mobility Report', global 5G subscriptions grew by approximately 160 million during the first quarter of 2024 alone, reaching a total of over 1.7 billion and creating a substantial requirement for shielded infrastructure hardware.

Segmental Insights

The automotive sector is emerging as the fastest-growing segment in the global metal foam market due to intensified demand for lightweight materials that enhance fuel efficiency. Manufacturers are increasingly utilizing aluminum foams to comply with strict emission standards set by authorities such as the European Commission and the United States Environmental Protection Agency. Additionally, the superior energy absorption properties of these foams make them ideal for safety applications, including crash boxes and bumpers. This adoption effectively balances the necessity for reduced vehicle weight with the requirement for robust structural safety.

Regional Insights

Asia Pacific holds a dominant position in the Global Metal Foam Market, supported by the expansive automotive and construction sectors in China and India. Manufacturers in the region increasingly utilize these materials to reduce vehicle weight and enhance safety, aligning with stringent emission standards and government mandates for electric mobility. The construction industry also drives demand by adopting metal foams for their effective sound and thermal insulation capabilities. This regional leadership is sustained by substantial investments in industrial infrastructure and a robust manufacturing base that prioritizes energy-efficient solutions.

Recent Developments

In June 2025, ERG Aerospace showcased its extensive portfolio of advanced open-cell foam solutions at the Paris Air Show, emphasizing the material's critical role in the aerospace sector. The company displayed a variety of custom-fabricated components, including high-efficiency heat exchangers and energy absorbers, all engineered using its signature Duocel foam technology. This exhibition provided a platform for the firm to demonstrate the versatility of its aluminum and copper foams in meeting rigorous flight hardware requirements. The event underscored the continued relevance of customizable metal foams in optimizing the thermal and structural performance of next-generation aircraft and space systems.
In February 2025, Advanced Materials Manufacturing declared its readiness to commence full-scale production of its proprietary composite metal foam (CMF) following a successful research and development phase. The company, which commercialized technology originally developed at a major research university, positioned this material as a superior alternative to traditional steel and aluminum due to its exceptional strength-to-weight ratio and impact resistance. This announcement marked the transition of the material from laboratory validation to industrial availability, targeting high-demand sectors such as automotive safety, aerospace structures, and military armor where lightweight, high-performance protection is increasingly required.
In August 2024, the Swiss startup Apheros unveiled a novel metal foam technology specifically engineered to address the thermal management challenges faced by modern data centers. The company introduced a high-porosity foam, manufacturable from copper, nickel, or stainless steel, which offers a surface area significantly larger than conventional cooling solutions. This product launch was positioned to support the increasing power demands of AI-driven data processing, with the new material promising to improve heat exchange efficiency by up to 90 percent. The development represented a strategic advancement in passive cooling technologies, aiming to reduce energy consumption and operational costs in high-performance computing infrastructure.
In July 2024, Cymat Technologies Ltd. announced a significant commercial milestone for its SmartMetal division by securing its first serial production order from an Asian military vehicle manufacturer. The agreement involved the supply of stabilized aluminum foam underbelly kits designed to provide critical blast protection for a national military fleet. This initial consignment was part of a projected fulfillment of 350 kits over a three-year period, marking the transition from a low-volume development phase to full-rate production. The collaboration highlighted the growing adoption of lightweight metallic foam solutions for enhancing survivability in defense applications without compromising vehicle mobility.

Key Market Players

ERG Aerospace Corporation
Aluminum King Co. Ltd
CYMAT Technologies Ltd.
Alantum
Ultramet
Mott Corporation
Mayser GmbH & Co. KG
Liaoning Rontec Advanced Material Technology Co. Ltd.
Shanxi Putai Aluminum Foam Manufacturing Co. Ltd.

By Material	By Application	By End-Use Industry	By Region
Aluminum Copper Nickel	Anti-Intrusion Bars Heat Exchangers Sound Insulation	Automotive Construction & Infrastructure Industrial	North America Europe Asia Pacific South America Middle East & Africa

Report Scope:

In this report, the Global Metal Foam Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

Metal Foam Market, By Material:

Aluminum
Copper
Nickel

Metal Foam Market, By Application:

Anti-Intrusion Bars
Heat Exchangers
Sound Insulation

Metal Foam Market, By End-Use Industry:

Automotive
Construction & Infrastructure
Industrial

Metal Foam Market, By Region:

North America

United States
Canada
Mexico

Europe

France
United Kingdom
Italy
Germany
Spain

Asia Pacific

China
India
Japan
Australia
South Korea

South America

Brazil
Argentina
Colombia

Middle East & Africa

South Africa
Saudi Arabia
UAE

Competitive Landscape

Company Profiles: Detailed analysis of the major companies present in the Global Metal Foam Market.

Available Customizations:

Global Metal Foam Market report with the given market data, TechSci Research offers customizations according to a company's specific needs. The following customization options are available for the report:

Company Information

Detailed analysis and profiling of additional market players (up to five).

Global Metal Foam Market is an upcoming report to be released soon. If you wish an early delivery of this report or want to confirm the date of release, please contact us at [email protected]

Table of content

1. Product Overview

1.1. Market Definition

1.2. Scope of the Market

1.2.1. Markets Covered

1.2.2. Years Considered for Study

1.2.3. Key Market Segmentations

2. Research Methodology

2.1. Objective of the Study

2.2. Baseline Methodology

2.3. Key Industry Partners

2.4. Major Association and Secondary Sources

2.5. Forecasting Methodology

2.6. Data Triangulation & Validation

2.7. Assumptions and Limitations

3. Executive Summary

3.1. Overview of the Market

3.2. Overview of Key Market Segmentations

3.3. Overview of Key Market Players

3.4. Overview of Key Regions/Countries

3.5. Overview of Market Drivers, Challenges, Trends

4. Voice of Customer

5. Global Metal Foam Market Outlook

5.1. Market Size & Forecast

5.1.1. By Value

5.2. Market Share & Forecast

5.2.1. By Material (Aluminum, Copper, Nickel)

5.2.2. By Application (Anti-Intrusion Bars, Heat Exchangers, Sound Insulation)

5.2.3. By End-Use Industry (Automotive, Construction & Infrastructure, Industrial)

5.2.4. By Region

5.2.5. By Company (2025)

5.3. Market Map

6. North America Metal Foam Market Outlook

6.1. Market Size & Forecast

6.1.1. By Value

6.2. Market Share & Forecast

6.2.1. By Material

6.2.2. By Application

6.2.3. By End-Use Industry

6.2.4. By Country

6.3. North America: Country Analysis

6.3.1. United States Metal Foam Market Outlook

6.3.1.1. Market Size & Forecast

6.3.1.1.1. By Value

6.3.1.2. Market Share & Forecast

6.3.1.2.1. By Material

6.3.1.2.2. By Application

6.3.1.2.3. By End-Use Industry

6.3.2. Canada Metal Foam Market Outlook

6.3.2.1. Market Size & Forecast

6.3.2.1.1. By Value

6.3.2.2. Market Share & Forecast

6.3.2.2.1. By Material

6.3.2.2.2. By Application

6.3.2.2.3. By End-Use Industry

6.3.3. Mexico Metal Foam Market Outlook

6.3.3.1. Market Size & Forecast

6.3.3.1.1. By Value

6.3.3.2. Market Share & Forecast

6.3.3.2.1. By Material

6.3.3.2.2. By Application

6.3.3.2.3. By End-Use Industry

7. Europe Metal Foam Market Outlook

7.1. Market Size & Forecast

7.1.1. By Value

7.2. Market Share & Forecast

7.2.1. By Material

7.2.2. By Application

7.2.3. By End-Use Industry

7.2.4. By Country

7.3. Europe: Country Analysis

7.3.1. Germany Metal Foam Market Outlook

7.3.1.1. Market Size & Forecast

7.3.1.1.1. By Value

7.3.1.2. Market Share & Forecast

7.3.1.2.1. By Material

7.3.1.2.2. By Application

7.3.1.2.3. By End-Use Industry

7.3.2. France Metal Foam Market Outlook

7.3.2.1. Market Size & Forecast

7.3.2.1.1. By Value

7.3.2.2. Market Share & Forecast

7.3.2.2.1. By Material

7.3.2.2.2. By Application

7.3.2.2.3. By End-Use Industry

7.3.3. United Kingdom Metal Foam Market Outlook

7.3.3.1. Market Size & Forecast

7.3.3.1.1. By Value

7.3.3.2. Market Share & Forecast

7.3.3.2.1. By Material

7.3.3.2.2. By Application

7.3.3.2.3. By End-Use Industry

7.3.4. Italy Metal Foam Market Outlook

7.3.4.1. Market Size & Forecast

7.3.4.1.1. By Value

7.3.4.2. Market Share & Forecast

7.3.4.2.1. By Material

7.3.4.2.2. By Application

7.3.4.2.3. By End-Use Industry

7.3.5. Spain Metal Foam Market Outlook

7.3.5.1. Market Size & Forecast

7.3.5.1.1. By Value

7.3.5.2. Market Share & Forecast

7.3.5.2.1. By Material

7.3.5.2.2. By Application

7.3.5.2.3. By End-Use Industry

8. Asia Pacific Metal Foam Market Outlook

8.1. Market Size & Forecast

8.1.1. By Value

8.2. Market Share & Forecast

8.2.1. By Material

8.2.2. By Application

8.2.3. By End-Use Industry

8.2.4. By Country

8.3. Asia Pacific: Country Analysis

8.3.1. China Metal Foam Market Outlook

8.3.1.1. Market Size & Forecast

8.3.1.1.1. By Value

8.3.1.2. Market Share & Forecast

8.3.1.2.1. By Material

8.3.1.2.2. By Application

8.3.1.2.3. By End-Use Industry

8.3.2. India Metal Foam Market Outlook

8.3.2.1. Market Size & Forecast

8.3.2.1.1. By Value

8.3.2.2. Market Share & Forecast

8.3.2.2.1. By Material

8.3.2.2.2. By Application

8.3.2.2.3. By End-Use Industry

8.3.3. Japan Metal Foam Market Outlook

8.3.3.1. Market Size & Forecast

8.3.3.1.1. By Value

8.3.3.2. Market Share & Forecast

8.3.3.2.1. By Material

8.3.3.2.2. By Application

8.3.3.2.3. By End-Use Industry

8.3.4. South Korea Metal Foam Market Outlook

8.3.4.1. Market Size & Forecast

8.3.4.1.1. By Value

8.3.4.2. Market Share & Forecast

8.3.4.2.1. By Material

8.3.4.2.2. By Application

8.3.4.2.3. By End-Use Industry

8.3.5. Australia Metal Foam Market Outlook

8.3.5.1. Market Size & Forecast

8.3.5.1.1. By Value

8.3.5.2. Market Share & Forecast

8.3.5.2.1. By Material

8.3.5.2.2. By Application

8.3.5.2.3. By End-Use Industry

9. Middle East & Africa Metal Foam Market Outlook

9.1. Market Size & Forecast

9.1.1. By Value

9.2. Market Share & Forecast

9.2.1. By Material

9.2.2. By Application

9.2.3. By End-Use Industry

9.2.4. By Country

9.3. Middle East & Africa: Country Analysis

9.3.1. Saudi Arabia Metal Foam Market Outlook

9.3.1.1. Market Size & Forecast

9.3.1.1.1. By Value

9.3.1.2. Market Share & Forecast

9.3.1.2.1. By Material

9.3.1.2.2. By Application

9.3.1.2.3. By End-Use Industry

9.3.2. UAE Metal Foam Market Outlook

9.3.2.1. Market Size & Forecast

9.3.2.1.1. By Value

9.3.2.2. Market Share & Forecast

9.3.2.2.1. By Material

9.3.2.2.2. By Application

9.3.2.2.3. By End-Use Industry

9.3.3. South Africa Metal Foam Market Outlook

9.3.3.1. Market Size & Forecast

9.3.3.1.1. By Value

9.3.3.2. Market Share & Forecast

9.3.3.2.1. By Material

9.3.3.2.2. By Application

9.3.3.2.3. By End-Use Industry

10. South America Metal Foam Market Outlook

10.1. Market Size & Forecast

10.1.1. By Value

10.2. Market Share & Forecast

10.2.1. By Material

10.2.2. By Application

10.2.3. By End-Use Industry

10.2.4. By Country

10.3. South America: Country Analysis

10.3.1. Brazil Metal Foam Market Outlook

10.3.1.1. Market Size & Forecast

10.3.1.1.1. By Value

10.3.1.2. Market Share & Forecast

10.3.1.2.1. By Material

10.3.1.2.2. By Application

10.3.1.2.3. By End-Use Industry

10.3.2. Colombia Metal Foam Market Outlook

10.3.2.1. Market Size & Forecast

10.3.2.1.1. By Value

10.3.2.2. Market Share & Forecast

10.3.2.2.1. By Material

10.3.2.2.2. By Application

10.3.2.2.3. By End-Use Industry

10.3.3. Argentina Metal Foam Market Outlook

10.3.3.1. Market Size & Forecast

10.3.3.1.1. By Value

10.3.3.2. Market Share & Forecast

10.3.3.2.1. By Material

10.3.3.2.2. By Application

10.3.3.2.3. By End-Use Industry

11. Market Dynamics

11.1. Drivers

11.2. Challenges

12. Market Trends & Developments

12.1. Merger & Acquisition (If Any)

12.2. Product Launches (If Any)

12.3. Recent Developments

13. Global Metal Foam Market: SWOT Analysis

14. Porter's Five Forces Analysis

14.1. Competition in the Industry

14.2. Potential of New Entrants

14.3. Power of Suppliers

14.4. Power of Customers

14.5. Threat of Substitute Products

15. Competitive Landscape

15.1. ERG Aerospace Corporation

15.1.1. Business Overview

15.1.2. Products & Services

15.1.3. Recent Developments

15.1.4. Key Personnel

15.1.5. SWOT Analysis

15.2. Aluminum King Co. Ltd

15.3. CYMAT Technologies Ltd.

15.4. Alantum

15.5. Ultramet

15.6. Mott Corporation

15.7. Mayser GmbH & Co. KG

15.8. Liaoning Rontec Advanced Material Technology Co. Ltd.

15.9. Shanxi Putai Aluminum Foam Manufacturing Co. Ltd.

16. Strategic Recommendations

17. About Us & Disclaimer

Report Description

Table of content

Figures and Tables

Frequently asked questions

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