Abstract: An improved apparatus and method of producing metal foam is provided which involves optimizing the natural convection of electrolyte through a foam being electroplated by inclining the foam during plating. A diagonal flow of electrolyte though the foam enhances electrolyte turnover within the foam while increasing electroplating efficiency. Further increases in plating efficiency are provided by shifting current density from higher plating zones to lower plating zones.

Abstract: A method for producing porous metal plated polymeric foam having uniform pore properties. Polymeric foam buns are horizontally cut along a longitudinal surface thereby lifting off a foam sheet. The sheet is spooled and then reticulated to remove any remaining cell walls and to round off the internal pore struts to enlarge the openings between the adjacent cells. The reticulated foam sheet is unwound and then plated. Slabs may be attached end to end and loop slitted and then reticulated. The resulting plated uniform foam provides a superior substrate for battery plaques and other applications.