A
metal foam structure is used for numerous energy applications such as battery, electrolyzer, fuel
cell, carbon capture, thermal management, and others due to its enhanced surface area to be utilized for improved efficiency. A net-shape
metal foam sheet or plate production with desired thicknesses without
cutting process is thus required to significantly reduce the manufacturing cost and to be more price competitive against other types of existing similar materials such as
carbon paper,
metal foil, mesh, plate, and others. In order to achieve this, a vertical
freeze casting is described where the
freeze casting of the metal
slurry takes place with the metal
slurry plate mold being placed vertically with respect to the ground, whereas the conventional
freeze casting process takes place with the metal
slurry plate mold being placed horizontally with respect to the ground.