Porcelain Foam – experiment and potential

Exploration & Development

Conventional ceramic foams are usually produced by pyrolizing polymer templates, creating a "ceramic copy" of the synthetic sponge. This project focuses on developing a more sustainable alternative: a direct foaming process for ceramic slip.

Through extensive testing, various additives, processing methods, and shaping techniques were combined. In this approach, air is introduced directly into the viscous mass, causing the slip to foam while organic additives stabilize the internal air bubbles. The primary challenge remains the sensitive drying process, which is currently undergoing further refinement.

Beyond developing the manufacturing process, the project also focused on processing the porcelain foam and exploring the material through design — shaping, post-processing, haptics, and aesthetics.

Material Properties & Application

Following comprehensive testing in the laboratories of the University of Bayreuth and Coburg University, the properties of the porcelain foam were systematically evaluated. Potential applications were then discussed in an interdisciplinary exchange across science, design, and industry.

Due to its ceramic base, the material is inherently heat-resistant and chemically stable. Pore size and porosity levels can be adjusted during production. A key feature is the ability to cast large-volume components that burn without cracking and remain lightweight due to the high air content. Additionally, the open-pore structure generates capillary action, allowing liquids to be absorbed and evenly released.

For practical application, the project focuses on two key fields: filtration for wastewater treatment and acoustic absorption for indoor spaces.

Translating Material Potential

Sustainable filtration is Charlotte Becker's application of Porcelain Foam as a filtration system for wastewater treatment. By adjusting pore size and porosity, the foam can filter a wide range of contaminants, including large microorganisms, from liquids and gases — making it viable for industrial, household, and humanitarian use. Its flexible, reusable filter elements can be cleaned for a long service life: contaminated liquid enters an upper container, drips through small openings onto the foam elements, and collects as clean water below.

Alongside it, Eva Conci translated the same material into Porous Silence, a modular acoustic absorber for architectural spaces.