Syntactic foam and Pressure–certified Microballoons
The strongest material in compression strength per-unit mass: pressure certified microballoons I have been fascinated with syntactic foam for many years. I filed a US patent in 1996 on a highly flexible syntactic foam based dive suit. Later I worked on syntactic foam in a polypropylene matrix (used for insulating oil pipelines under the ocean). And I learned all about the syntactic foam used on submarines. I have applied for quite a few SBIR grants based on some aspect of hollow glass microballoons or syntactic foam based on polymers. One part of fly ash from coal burning power plants are called cenospheres; cenospheres are not manufactured on purpose, and as a byproduct they're potentially very cheap. Their molecular makeup also makes them higher melting than the typical glass microballoons that are in commerce today, so cenospheres can successfully be mixed with molten aluminum for example, whereas typical glass microballoons soften too much to be mixed with molten alumin...