High-purity 99.5% copper foam with 85-95% porosity for lithium-ion battery electrodes, thermal management systems, and EMI shielding applications. Customizable PPI (100-500) and dimensions.
High-purity 99.5% copper foam with uniform 3D porous structure for advanced applications.
Copper Foam Specifications: 99.5% purity, 95% porosity, 110 PPI, 2.0mm thickness
Ideal for battery electrodes, thermal management, and EMI shielding applications
Copper foam combines exceptional thermal conductivity (15-25 W/m·K) with high surface area for superior performance in energy storage and thermal management applications.
Copper's exceptional thermal conductivity (400 W/m·K bulk) combined with high surface area enables efficient heat transfer in compact designs. Effective thermal conductivity: 15-25 W/m·K depending on porosity.
High electrical conductivity (10³-10⁴ S/cm) makes copper foam ideal for battery current collectors, electrodes, and EMI shielding applications. 2-3x higher conductivity than nickel foam.
3D structure increases active material loading by 200-300% compared to flat copper plates. Research shows 38% higher power output and improved lithium plating uniformity for longer cycle life.
High porosity (85-95%) creates a lightweight material with excellent strength-to-weight ratio. Density: 0.5-1.2 g/cm³ (3-8% of solid copper).
Adjustable pore size (100-500 PPI), porosity, thickness (0.5-10mm), and surface treatments to meet specific application requirements. Custom dimensions available.
Fully recyclable material with lower environmental impact compared to polymer-based foams and composites. RoHS & REACH compliant for global markets.
Performance comparison to help you select the optimal material for your application.
| Property | Copper Foam | Nickel Foam | Aluminum Foam | Best For | |||||
|---|---|---|---|---|---|---|---|---|---|
| Thermal Conductivity | 15-25 W/m·K | 5-15 W/m·K | 5-10 W/m·K | Copper: Heat sinks, thermal management | Electrical Conductivity | 10³-10⁴ S/cm | 10²-10³ S/cm | 10³-10⁴ S/cm | Copper: Battery anodes, current collectors |
| Relative Cost | Medium | High | Low | Aluminum: Cost-sensitive projects | |||||
| Corrosion Resistance | Good | Excellent | Good (with coating) | Nickel: Alkaline environments | |||||
| Weight (Density) | 0.5-1.2 g/cm³ | 0.4-0.9 g/cm³ | 0.3-0.8 g/cm³ | Aluminum: Weight-critical applications | |||||
| Max Temperature | 400°C | 600°C | 250°C | Nickel: High-temperature applications |
Our materials engineers provide free consultation to help you select optimal copper foam properties for your application. Similar to our nickel foam for batteries, copper foam offers excellent conductivity but with superior thermal properties for anode applications.
or Call +1-406-479-0215Our copper foam is manufactured to precise specifications using advanced electrochemical deposition methods, ensuring consistent quality and performance across all applications.
| Property | Specification | Test Method |
|---|---|---|
| Base Material | 99.5% Pure Copper (99.9% available) | ASTM E1473 |
| Porosity | 85-95% (customizable) | ASTM D2856 |
| Pore Density (PPI) | 100-500 pores per inch | ASTM D3574 |
| Thickness | 0.5mm - 10.0mm | ASTM D374 |
| Density | 0.5 - 1.2 g/cm³ | ASTM D1622 |
| Thermal Conductivity | 15-25 W/m·K (effective) | ASTM E1461 |
| Electrical Conductivity | 10³ - 10⁴ S/cm | ASTM D257 |
| Compressive Strength | 3.0-8.0 MPa | ASTM D1621 |
| Maximum Temperature | Up to 400°C (with coating) | ASTM D648 |
Copper foam is available in sheets, rolls, custom die-cut parts, and fabricated assemblies. Standard sheet sizes up to 600mm × 1200mm. Custom dimensions and shapes available upon request.
Copper foam's unique properties make it suitable for a wide range of industrial and technological applications.
Copper foam for lithium-ion battery anodes offers 38% higher power output compared to traditional copper foil. Studies show enhanced lithium plating uniformity and 200-300% increased active material loading.
Heat exchangers, heat sinks, and thermal interface materials for electronics cooling. Copper foam provides 3x higher thermal conductivity than aluminum foam for high-performance applications.
Electromagnetic interference shielding for electronics enclosures, aerospace components, and telecommunications equipment. For EMI shielding requirements, also explore our dedicated EMI shielding solutions.
High-efficiency filters for gases and liquids, catalyst supports, and acoustic absorption materials. High surface area (＞1000 m²/g effective) enables superior filtration performance.
Catalyst supports, reaction media, and porous electrodes for chemical reactors and electrochemical processes. Copper foam's high surface area and thermal stability make it ideal for catalytic applications.
Lightweight structural components, thermal management systems, and EMI shielding for demanding environments. Copper foam enables weight reduction while maintaining performance.
Challenge: Traditional copper foil limited anode material loading and power output.
Solution: Custom 110 PPI copper foam, 1.0mm thickness with 98% porosity.
Results:
Challenge: Traditional heat sinks insufficient for compact avionics cooling.
Solution: Custom copper foam heat sink with integrated phase-change material.
Results:
Our engineering team will help you select the right specifications and provide custom solutions for your specific requirements. Get a free technical consultation.
Evaluate our high-performance copper foam for your application with our comprehensive sample kit.
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For custom material specifications, larger sample quantities, or production volume quotations, please fill out the form below.
Need help selecting specifications? Contact our materials experts for assistance.
Our team of materials engineers provides comprehensive support from material selection to application integration.
Our engineers analyze your requirements and recommend optimal copper foam specifications for your specific application.
engineering@prometheanfoam.comWe specialize in custom copper foam production with tailored porosity, pore size, thickness, and surface treatments.
custom@prometheanfoam.comComplete material testing and characterization services including porosity analysis, thermal conductivity, and mechanical properties.
testing@prometheanfoam.comMonday - Friday: 8:00 AM - 6:00 PM MST
Saturday: 9:00 AM - 1:00 PM MST
Emergency technical support available for critical projects
Find answers to common questions about copper foam and our services.
PrometheanFoam supplies high-purity copper foam worldwide. Order our $79 sample kit or request a custom quote for research quantities starting at 10 sheets. We ship to 50+ countries with 3-5 day delivery to the US. For bulk production orders, we offer competitive pricing with MOQ starting at 100 sheets.
Copper foam pricing varies by specification (purity, PPI, thickness). Standard 99.5% pure, 110 PPI foam ranges from $120-180/m² for production volumes (100+ sheets). Research-grade 99.9% pure copper foam starts at $200/m². Contact us for current pricing based on your specific requirements and volume.
For samples: 1-5 sheets (starting at $79 for our sample kit). For production: 10 sheets minimum for standard specifications, 100 sheets for custom specifications. Larger volumes receive volume discounts - contact our sales team for specific MOQ based on your application requirements.
PPI (pores per inch) affects surface area and permeability:
While copper foam has good corrosion resistance, it's not recommended for highly alkaline environments (pH >10). For alkaline applications such as nickel-metal hydride batteries or alkaline fuel cells, nickel foam is preferred. Copper foam excels in neutral to slightly acidic conditions typical of lithium-ion batteries and PEM fuel cells.
Effective thermal conductivity ranges from 15-25 W/m·K depending on porosity:
For anodes: Yes. Copper foam offers:
Yes, copper foam can be joined using several methods:
Several cutting methods are suitable for copper foam:
Yes, every order includes comprehensive documentation:
We offer multiple purity grades:
Our comprehensive testing protocols include: