Introduction: Finding the Right Metal Foam Partner in the United States
Metal foam — including aluminum foam, nickel foam, copper foam, and open-cell porous metal materials — has become an essential engineering material for EV battery electrodes, fuel cells, heat exchangers, EMI shielding, energy absorption, filtration, thermal management, and lightweight structural design in 2026. For procurement managers, design engineers, and R&D specialists sourcing metal foam in the USA, identifying reliable domestic manufacturers and suppliers is critical to ensuring material consistency, technical support, and stable delivery timelines.
This guide profiles the top 6 metal foam manufacturers and suppliers in the USA in 2026 — ERG Aerospace Corporation, Ultramet, PrometheanFoam, Reade Advanced Materials, American Elements, and ALUFOAM (MegaKer LLC). Each company is evaluated on its metal foam product portfolio, manufacturing capabilities, main markets, and customization options, helping you quickly shortlist qualified U.S. suppliers for aluminum foam, nickel foam, copper foam, and other porous metal applications.
| Rank | Company | Location | Metal Foam Business | Type |
|---|---|---|---|---|
| 1 | ERG Aerospace Corporation | Nevada / California | Aluminum Foam, Copper Foam, Open-Cell Metal Foam (Duocel®) | Manufacturer |
| 2 | Ultramet | California | Refractory Metal Foam, Open-Cell Foam, Ceramic and Carbon Foam | Manufacturer |
| 3 | PrometheanFoam (Promethean Metal Foam LLC) | Wyoming | Nickel Foam, Copper Foam, Iron-Nickel Foam, Custom Metal Foam Sheets | Manufacturer |
| 4 | Reade Advanced Materials | Rhode Island | Aluminum Foam, Copper Foam, Nickel Foam, Open-Cell Metal Foam | Manufacturer / Supplier |
| 5 | American Elements | California | Copper Foam, Nickel Foam, Aluminum Foam, NiCrAl Foam | Manufacturer / Supplier |
| 6 | ALUFOAM (MegaKer LLC) | Delaware | Aluminum Foam, Open-Cell & Closed-Cell Aluminum Foam | Manufacturer / Supplier |
Top 6 Metal Foam Manufacturers and Suppliers in the USA: Company Profiles
1. ERG Aerospace Corporation — USA
Company Overview: ERG Aerospace Corporation, with corporate headquarters in Nevada and manufacturing operations in Oakland, California, is one of the world's most experienced open-cell metal foam manufacturers. Established in 1967, the company is the original developer and sole producer of Duocel® metal foam, a proprietary reticulated porous metal technology with a heritage spanning nearly six decades. ERG's metal foams have a long flight history on aerospace and defense programs, making the company the quality benchmark in the porous metals industry. ERG is an AS9100-certified, Service-Disabled Veteran-Owned Small Business with 100% U.S.-based manufacturing across its two production facilities.
Metal Foam Products: ERG manufactures open-cell, solid-ligament metal foams in aluminum (6101 alloy), copper, nickel, and specialty metals, available in a wide range of pore sizes and relative densities. The company also engineers finished foam components such as compact heat exchangers, air-oil separators, flame arrestors, energy absorption modules, catalyst supports, and EMI shielding structures. Duocel® foam is also available in carbon and ceramic variants including silicon carbide for extreme-environment applications.
Key Products: Duocel® Aluminum Foam, Duocel® Copper Foam, Duocel® Nickel Foam, Duocel® Reticulated Vitreous Carbon Foam, Duocel® foam heat exchangers, crash and energy absorption modules, bird strike protection systems, and battery electrode foam.
Main Markets: Aerospace and defense, power electronics and IGBT cooling, energy, semiconductor manufacturing, medical and scientific instruments, filtration, and environmental control — serving customers across North America, Europe, and Asia from its California and Nevada facilities.
Why Consider ERG Aerospace: Flight-proven heritage, aerospace-grade quality control, deep engineering support for custom foam components, and one of the broadest material and pore-size ranges in the industry make ERG the reference supplier for high-reliability open-cell metal foam applications. Nearly 60 years of continuous process refinement, in-house testing capabilities, and a team of experienced engineers capable of optimizing foam specifications for performance and manufacturability give customers confidence in mission-critical applications.
2. Ultramet — USA
Company Overview: Ultramet, headquartered in Pacoima, California, is an advanced materials company founded in 1970 that develops high-temperature material solutions for government and commercial markets driven by extreme environments. The company specializes in chemical vapor deposition (CVD) technology, refractory metal coatings, ceramic matrix composites, and open-cell refractory foams. Ultramet has been recognized as a world leader in rhenium products and has delivered advanced material systems for NASA, the Department of Defense, and leading aerospace and industrial companies for over five decades.
Metal Foam Products: Ultramet manufactures refractory open-cell foams — a new class of low-density porous materials for aerospace and industrial applications. Using a proprietary process that pyrolyzes polymer foam into reticulated vitreous carbon foam, Ultramet then infiltrates refractory metals and ceramics into the structure to tailor material properties. The company produces open-cell foams in tungsten, rhenium, tantalum, molybdenum, niobium, carbon, and ceramic compositions, as well as foam-based heat sinks, mirrors, fuel injectors, and noise reduction components.
Key Products: Refractory open-cell metal foams (tungsten, rhenium, tantalum, molybdenum, niobium), reticulated vitreous carbon foam, ceramic and metal CVD-coated foams, foam-based thermal management components, hypersonic vehicle structures, and propulsion system components.
Main Markets: Aerospace, defense, hypersonic vehicles, rocket propulsion, nuclear power, chemical processing, semiconductor manufacturing, and high-temperature industrial applications — primarily serving U.S. government agencies, prime aerospace contractors, and advanced technology companies.
Why Consider Ultramet: For extreme-environment applications where conventional metal foams cannot survive, Ultramet's refractory foam technology offers unmatched temperature capability and material customization. The company's five decades of CVD expertise, extensive SBIR-funded R&D portfolio, and proven track record on defense and aerospace programs make it the go-to source for specialized refractory metal foam solutions operating above 3000°F in hypersonic, propulsion, and high-temperature energy systems.
3. PrometheanFoam (Promethean Metal Foam LLC) — USA
Company Overview: PrometheanFoam, operating as Promethean Metal Foam LLC from Sheridan, Wyoming, is a U.S. manufacturer specializing in custom foam metal solutions for battery, electronics, defense, and industrial applications. Founded in 2010, the company has delivered more than 500 custom solutions and operates an ISO 9001 certified and IATF 16949 compliant U.S. factory. PrometheanFoam's business model is built around simplifying the sourcing process: customers describe their application in plain English, and the company's engineers handle all R&D, material selection, tooling, and production.
Metal Foam Products: PrometheanFoam manufactures open-cell metal foams from six standard base materials plus custom alloys, available in PPI densities from 10 to 500, porosity from 70% to 95%, thickness from 0.5 to 50 mm, and any custom geometry. Core products include nickel foam for battery electrodes, copper foam for thermal management, aluminum foam for casting filters, iron-nickel foam, stainless steel foam, and metal foam sheets for EMI shielding. The company offers 7-day prototype turnaround with no minimum order quantity on samples.
Key Products: Nickel foam (99.5% purity) for battery electrodes, copper foam for heat exchangers and cooling, iron-nickel foam for specialty applications, aluminum foam for casting filters and lightweight structures, custom metal foam sheets, EMI shielding foam materials, and semi-finished foam components.
Main Markets: EV and battery manufacturers, defense and aerospace electronics, data centers and power electronics, semiconductor fabrication, aluminum foundries, commercial HVAC, and research laboratories — serving customers across the United States and internationally.
Why Consider PrometheanFoam: For buyers who need custom metal foam without in-house materials expertise, PrometheanFoam eliminates the technical barrier to entry. The company's 24-hour response time, 7-day prototype turnaround, no MOQ on samples, and full-service engineering support — from concept to production — make it ideal for rapid prototyping and small-to-medium volume production runs. Its ISO 9001 certification and IATF 16949 compliance assure quality consistency for automotive and defense applications.
4. Reade Advanced Materials — USA
Company Overview: Reade Advanced Materials, headquartered in Providence, Rhode Island, is one of the world's premier distributors of specialty chemical solids and advanced materials, with a history dating back to 1883. As a Service-Disabled Veteran-Owned Small Business (SDVOSB), Reade provides global sourcing, toll processing, toll packaging, and custom material solutions for industries requiring high-purity metals, ceramics, and porous materials. The company's multi-lingual team supports customers across North America, Europe, and Asia with technical documentation, safety data sheets, and rapid quote turnaround.
Metal Foam Products: Reade supplies a comprehensive range of metal foams including aluminum foam, copper foam, nickel foam, molybdenum cellular foam, and open-cell reticulated foam. Aluminum metal foam is available as fully customizable rigid, open-pore three-dimensional networks of interconnected solid aluminum ligaments with high strength-to-weight ratios. The company also offers CVD-coated reticulated vitreous carbon foams and custom porous metal products in various pore densities from 10 to 100 PPI.
Key Products: Aluminum metal foam panels (4.0" x 4.0" x 0.5" or 0.25" or 0.125"), open-cell metal foam, copper foam, nickel foam, molybdenum cellular foam, reticulated vitreous carbon foam, and custom metal foam powder and structures.
Main Markets: Aerospace, defense, energy, electronics, chemical processing, automotive, filtration, thermal management, and research institutions — serving customers worldwide through its global sourcing network and multiple language support capabilities.
Why Consider Reade Advanced Materials: For buyers seeking both standard and hard-to-find metal foam materials, Reade's 140-year history, global sourcing infrastructure, and SDVOSB status provide supply chain reliability and diversity compliance advantages. The company's ability to source, process, and package metal foams to customer specifications — combined with rapid RFQ response and comprehensive technical documentation — makes it a valuable partner for both prototype development and production volumes.
5. American Elements — USA
Company Overview: American Elements, headquartered in Santa Monica, California, is the world's largest manufacturer devoted exclusively to advanced materials in both industrial bulk and laboratory/research quantities. Founded as a toll chemical manufacturer and refiner serving U.S. mining companies, the company has grown into a global supplier of more than 35,000 products including metals, alloys, ceramics, compounds, and composites. With production facilities in Salt Lake City, Utah; Monterrey, Mexico; China; and Manchester, UK, American Elements has been a key resource for corporate, government, and academic new product development for over a quarter century.
Metal Foam Products: American Elements manufactures and supplies metal foams in copper, nickel, aluminum, and specialty alloys including nickel-chromium-aluminum (NiCrAl) foam. Products feature high porosity typically ranging from 75% to 95% of volume consisting of void spaces. The company offers standard and ultra-high purity grades (99% to 99.9999%), various pore structures, and packaging options from research quantities to industrial bulk shipments including palletized pails, fiber and steel drums, and one-ton super sacks.
Key Products: Copper foam, nickel foam (CAS 7440-02-0), aluminum foam, nickel-copper foam, nickel-chromium-aluminum (NiCrAl) foam, high-purity metal foams for catalysis and battery applications, and specialty porous metal materials.
Main Markets: Battery and fuel cell manufacturers, catalysis and chemical processing, thermal management, aerospace, electronics, academic and government research institutions, and Fortune 500 corporations — serving customers across North America, South America, Europe, and Asia-Pacific.
Why Consider American Elements: For applications requiring ultra-high purity materials, rare alloy compositions, or certified research-grade documentation, American Elements offers unmatched catalog depth and technical expertise. The company's ability to scale from laboratory quantities to industrial production, comprehensive certificates of analysis, and immediate availability of most volumes make it particularly valuable for R&D programs transitioning to commercialization and for specialized applications where material purity is critical.
6. ALUFOAM (MegaKer LLC) — USA
Company Overview: ALUFOAM, operated by MegaKer LLC from its Delaware office at 2915 Ogletown Road, is a U.S.-based manufacturer and supplier of high-performance aluminum foam materials for architectural, structural, and industrial applications. Backed by technology partner CSI Institute Ltd, the company has spent 20 years developing scalable aluminum foam manufacturing capabilities and composite material technologies. ALUFOAM has positioned itself as a disruptive force in the metal foam industry, focusing on large-format aluminum foam products and multi-material composite solutions for demanding structural and design applications.
Metal Foam Products: ALUFOAM specializes in aluminum foam products with controlled density (from 200 kg/m³ to 500 kg/m³ and on demand), cell sizes from 2 mm to 20 mm, and both closed-cell and open-cell configurations. The company produces large-format blocks from 600 mm x 1200 mm x 600 mm up to 1200 mm x 2400 mm, and offers custom dimensions on demand. ALUFOAM aluminum foam can be integrated with other materials including stainless steel and aluminum honeycomb for composite structures in civil, defense, superstructure, automotive, naval, and aerospace applications.
Key Products: Closed-cell aluminum foam blocks and panels, open-cell aluminum foam, large-format aluminum foam sheets, aluminum foam sandwich composites, custom-density aluminum foam products, and architectural aluminum foam cladding materials.
Main Markets: Architecture and construction, automotive and transportation, naval and marine, aerospace and defense, civil engineering superstructures, acoustic design, and lightweight structural applications — serving customers primarily in North America and Europe.
Why Consider ALUFOAM (MegaKer LLC): For projects requiring large-format aluminum foam panels or custom composite structures, ALUFOAM's ability to produce blocks up to 1200 mm x 2400 mm sets it apart from smaller-format suppliers. The company's flexible density control, both open and closed cell options, and capability to combine aluminum foam with other structural materials make it a strong partner for architectural, automotive, and marine applications where traditional aluminum foam sizes are insufficient.
FAQ: Metal Foam Manufacturers and Suppliers in the USA
1. Who are the top metal foam manufacturers and suppliers in the USA in 2026?
The leading metal foam manufacturers and suppliers in the USA in 2026 include ERG Aerospace Corporation, Ultramet, PrometheanFoam, Reade Advanced Materials, American Elements, and ALUFOAM (MegaKer LLC). These companies offer aluminum foam, nickel foam, copper foam, open-cell metal foam, refractory metal foam, and customized porous metal materials for industrial applications ranging from battery electrodes to aerospace thermal management.
2. Where can I buy metal foam from a manufacturer in the USA?
Buyers can purchase metal foam directly from U.S. manufacturers and suppliers specializing in aluminum foam, nickel foam, copper foam, and other porous metal materials. When sourcing metal foam in the USA, compare material grade, pore size, porosity, density, thickness, minimum order quantity, customization options, and domestic delivery capabilities. Direct contact with manufacturers like ERG Aerospace, PrometheanFoam, or Reade Advanced Materials typically provides the most competitive pricing and technical support for production volumes.
3. Who are the leading aluminum foam manufacturers in the USA?
Leading U.S. aluminum foam manufacturers and suppliers include ERG Aerospace Corporation and ALUFOAM (MegaKer LLC), along with PrometheanFoam and Reade Advanced Materials providing open-cell and closed-cell aluminum foam products. Aluminum foam is commonly used for lightweight structures, energy absorption, vibration damping, sound attenuation, thermal management, EMI shielding, and aerospace applications where weight reduction is critical.
4. Are there nickel foam and copper foam suppliers in the USA?
Yes. Several U.S. metal foam suppliers offer nickel foam and copper foam for applications such as batteries, fuel cells, electrodes, filtration, heat transfer, thermal management, and electromagnetic shielding. PrometheanFoam, Reade Advanced Materials, American Elements, and ERG Aerospace are examples of U.S.-based suppliers with products related to these porous metal materials. Nickel foam is particularly critical for EV battery and fuel cell manufacturers, while copper foam excels in thermal management and heat exchanger applications.
5. How do I choose the best metal foam supplier in the USA?
To choose the best metal foam supplier in the USA, evaluate its manufacturing capabilities, material selection, pore structure, porosity, density, product consistency, customization services, quality control, production capacity, and lead time. For large-volume or specialized projects, requesting samples, technical datasheets, and application-specific recommendations can help verify whether the supplier meets your requirements. Additionally, consider certifications (ISO 9001, AS9100), engineering support capabilities, and domestic manufacturing status for supply chain security and government contract compliance.
Conclusion: Selecting Your Metal Foam Partner in 2026
The U.S. metal foam industry in 2026 offers a diverse and mature supplier landscape, with companies specializing in everything from flight-proven open-cell aluminum foam for aerospace to ultra-high-purity nickel foam for advanced battery applications. Whether your priority is aerospace-grade quality control from ERG Aerospace, extreme-temperature refractory foams from Ultramet, rapid custom prototyping from PrometheanFoam, or large-format aluminum panels from ALUFOAM, the American market provides reliable domestic sources for nearly every porous metal requirement.
As global demand for metal foam accelerates across EV batteries, hydrogen technologies, power electronics, and sustainable construction, sourcing teams increasingly look beyond domestic borders to secure the best combination of quality, customization capability, and cost-effectiveness. For buyers evaluating both U.S. and international suppliers, HY Metal Foam (Huayan Intelligent Technology) offers complementary capabilities in nickel foam, copper foam, and aluminum foam production — with advanced porous material technology, customized OEM/ODM manufacturing, strict quality management, and reliable global supply capability. Requesting samples and technical datasheets from multiple suppliers, both domestic and international, remains the most effective strategy for validating performance and building a resilient metal foam supply chain in 2026.
