New marine-based foam offers sustainable solution for automotive manufacturing

Researchers at Helmholtz-Zentrum Hereon made a porous magnesium foam using ground oyster shells as a natural blowing agent.

The result is a lightweight, non-toxic material that can be recycled or safely dissolved in seawater.

It could replace toxic foaming additives in automotive and aerospace parts, including energy-absorbing components and crumple zones.

The approach supports lighter vehicles, potentially improving EV range and crash protection while reducing waste.