Current applications for syntactic foam include buoyancy modules for marine riser tensioners, remotely operated underwater vehicles (ROVs), autonomous underwater vehicles (AUVs), deep-sea exploration, boat hulls, and helicopter and airplane components.
Cementitious syntactic foams have also been investigated as a potential lightweight structural composite material. These materials include glass microspheres dispersed in a cement paste matrix to achieve a closed cell foam structure, instead of a metallic or a polymeric matrix. Cementitious syntactic foams have also been tested for their mechanical performance under high strain rate loading conditions to evaluate their energy dissipation capacity in crash cushions, blast walls, etc. Under these loading conditions, the glass microspheres of the cementitious syntactic foams did not show progressive crushing. Ultimately, unlike the polymeric and metallic syntactic foams, they did not emerge as suitable materials for energy dissipation applications. Structural applications of syntactic foams include use as the intermediate layer (that is, the core) of sandwich panels.
Though the cementitious syntactic foams demonstrate superior specific strength values in comparison to most conventional cementitious materials, it is challenging to manufacture them. Generally, the hollow inclusions tend to buoy and segregate in the low shear strength and high-density fresh cement paste. Therefore, maintaining a uniform microstructure across the material must be achieved through a strict control of the composite rheology. In addition, certain glass types of microspheres may lead to an alkali silica reaction. Therefore, the adverse effects of this reaction must be considered and addressed to ensure the long-term durability of these composites.
Other applications include;
*Deep-sea buoyancy foams. A method of creating submarine hulls by 3D printing was developed in 2018.
*Thermoforming plug assist
*Radar transparent materials
*Acoustically attenuating materials
*Cores for sandwich composites
*Blast mitigating materials
*Sporting goods such as bowling balls, tennis rackets, and soccer balls.