Automobil construction

Aluminum foam is excellent at absorbing vibrations, blows and hits, which is why it is predestined for usage in rigid and crash-relevant areas.

In particular in automobile construction, aluminum foam can be pioneering for carrying structures from personal vehicles and utility vehicles, because it provides higher deformation work compared to pure steel profiles so that the material is first impaired after a very high degree of deformation.

Application areas

Reinforcing elements in the body area, for example,

  • Foamed bumpers
  • Connecting areas, joints
  • Lateral protection structure
  • Door sills
  • Roof racks, side members, cross members
  • Area elements, for example, roof bows


  • High energy absorption in the event of a crash through plastic deformation
  • Bending and compressing behaviour of steel profiles is improved greatly
  • Weight savings
  • Excellent vibration dampening, for example, motor vibrations
  • Increase in torsional stiffness of the complete body by approx. 10 %
  • Can be recycled

Aluminum foam crash absorber in the luggage net of an Audi Q7 (3D shaped element)

3D shaped element for a shock absorber

Application Example Battery box made of aluminum foam

The use of lightweight components is increasingly gaining importance for the production of vehicles. Forward-looking developments of electrically driven vehicles only reach the effi ciency goals through the consistent usage of extremely light materials such as aluminum. Aluminum foam combines many advantages such as extreme lightness, formability, recyclability as well as amazing absorption and conductivity and is therefore ideal for the automobile industry of the future. A trendsetting development of the Havel metal foam is the battery box for electric vehicles. Low weight, good crash behaviour, high stiffness and possibilities for temperature regulation predestine these newly developed vehicle components for use in modern automobile manufacturing.

The battery box from the Havel LiteĀ® series is made completely of aluminum foam sandwiches. Through the versatile properties of the foam, the product is perfectly ideal for use as an encasing of batteries in the automobile industry. Bars in the form of aluminum foam sandwiches between the batteries act as spacers and crash absorbers. Profiles or pipes can be integrated in the aluminum foam, for example, for battery cooling. Low weight and good stiffness are other advantages of the material.

Aluminum foam sandwiches with integrated profiles for battery cooling

Material: Aluminum foam, Dimensions: 975 mm x 536 mm x 55 mm, Material thickness: 4 mm

Aluminum sandwiches between batteries as spacers and crash absorbers

Sketch on crash behaviour/crash absorption Standard DIN 50134 - compression test of metallic cell material