The following are some current research directions into new processes and materials.
Microcellular extrusion allows for the continuous production of microcellular foam.
Constrained foaming is a scalable process to create thick load-bearing foam panels.
Open-Celled microcellular foams could be used in a variety of applications including biomedical tissue scaffolding.
Nanofoams are an extension of microcellular polymer technology with pore sizes below the micrometer range.  The Microcellular Plastics Lab has recently reported production of nanofoams in PEI.