Fabrication of Auxetic Foam Sheets for Sports Applications

Auxetic materials have a negative Poisson's ratio, which can enhance other properties. Greater indentation resistance and energy absorption, as well as synclastic curvature, could lend auxetic materials well to protective sports equipment and clothing. Sheets of foam often form padding within protective equipment, but producing large homogenous auxetic foam samples is challenging. The aim of this work was to investigate techniques to fabricate large thin sheets of auxetic foam, to facilitate future production and testing of prototype sports equipment utilizing this material. A mold was developed to fabricate sheets of auxetic foam - with planar dimensions measuring 350x350mm - using the thermo-mechanical process. The mold utilized through-thickness rods to control lateral compression of foam. Sheets of auxetic foam measuring 10x350x350mmd were fabricated and characterized. Each sheet was cut into nine segments, with density measurements used to determine how evenly the foam had been compressed during fabrication. Specimens cut from corner and centre segments were subject to quasi-static extension up to 30% to obtain stress versus strain relationships, with Digital Image Correlation used to determine Poisson's ratio. Specimens cut from the corner tended to have a marginally higher density, lower stiffness and more consistent negative Poisson's ratio compared to those from the centre, indicating some inconsistency in the conversion process. Future work could look to improve fabrication techniques for large thin homogenous sheets of auxetic foam.