Foam Production Research Articles

Valorization of Arbutus unedo L. Bark Through Chemical Composition Analysis, Liquefaction, and Bio-Based Foam Production

Arbutus unedo (strawberry tree) is a small Mediterranean tree capable of vigorous regrowth after disturbances like fire. Traditionally used for biomass fuel, its bark and branches hold potential for higher-value products through ecovalorization into liquid mixtures that could replace petroleum-based materials. This study aimed to explore the chemical composition of various components of Arbutus unedo and to produce a liquefied material from its internal (IB) and external bark (EB). Chemical compositions of internal and external bark were determined using TAPPI standards including ash, extractive content, lignin, and cellulose. Metal cations were analyzed by ICP. Liquefaction of bark was optimized in a PARR reactor, evaluating factors such as particle size, temperature, and time, and the best polyols were monitored by FTIR-ATR. Polyurethane foams were made with internal and external bark materials liquefied by polymerization with isocyanate, a catalyst, and water as a blowing agent. Results showed that EB has a higher extractive and lignin content, while IB contains more cellulose. Liquefaction yields were higher for IB (74%) than EB (68%), with IB yielding polyols that produced stronger and more resilient foams with higher compressive strength and modulus of elasticity. Mechanical properties of the foams were influenced by the NCO/OH ratio and catalyst levels. Overall, the internal bark demonstrated superior performance for foam production, highlighting its potential as an eco-friendly alternative to petroleum-derived materials.

High-performance bio-based foam from agricultural waste luffa seed oil polyols

The present study aimed to develop eco-friendly polyurethane viscoelastic foam (PVF) with enhanced tear strength while preserving softness, comfort, and safety by utilizing bio-based polyols derived from luffa seed oil (LSO). Two types of bio-based polyols (PLSO-D and PLSO-M) were synthesized through the epoxidation process using diethylene glycol (DEG) and methanol (MeOH), respectively, for the production of LSO-based polyurethane viscoelastic foams (LSO-PVFs). The analyses revealed that these polyols exhibited high dispersion, appropriate hydroxyl values, and contained by-products such as oligomeric esters of fatty acids that facilitated physical and chemical crosslinking. LSO-PVFs demonstrated a uniform and fine cell structure with abundant open-cells, thick cell walls (55.5–76.6µm), and high apparent density (48.7–50.7kg/m3). Moreover, they exhibited enhanced tensile and tear strength (increasing up to 200% compared to petroleum-based PVFs), lower water absorption, excellent mildew resistance at 10% PLSO substitution. Additionally, these factors endowed LSO-PVFs with low indentation hardness and good bottom support performance, characterized by a compressive deflection coefficient of 2.30–3.54. This approach presents a sustainable alternative for foam production that offers comfort, durability while promoting the value-added utilization of agricultural waste.

Facile preparation of solid gelatin foams by a water-lean batch foaming process.

Existing polystyrenic and polyolefinic packaging foams are non-biodegradable, and persist in the environment for hundreds of years. Gelatin foams are an interesting alternative, given their biodegradability, biocompatibility, solution-based processability, low cost, and non-toxicity. However, current methods for preparing gelatin foams, such as freeze-drying, microfluidic foaming, and batch foaming, are not suitable for high-volume production. In this context, we report the preparation of solid gelatin foams by a water-lean batch foaming process that involves simply mixing bloomed gelatin with a blowing agent, selected from inorganic bicarbonates and cyclic organic carbonates, and heating the resulting mixture in an open mold. The foaming was primarily attributed to CO2 produced by blowing agents, while the transformation from discrete gelatin granules to a continuous foam was facilitated by the melting, flowing, and fusion of the bloomed gelatin granules into a homogeneous mass upon heating. This process is simple, inexpensive, sustainable, and versatile, making it highly suitable for high-volume production of biodegradable foams, particularly for use in loose-fill packaging applications.

Innovative fabrication of eco-friendly bio-based foam from sugarcane bagasse and sodium alginate with enhanced properties and sustainable applications for plastic replacement

Foam materials possess notable features, including low density, high porosity, low thermal conductivity, and high impact resistance, making them extensively used in various sectors such as construction, transportation, water treatment, and packaging. However, the majority of commercial foam materials are derived from synthetic polymers based on fossil fuels, which raises concerns regarding health and ecology. In this work, we present a straightforward and scalable approach (physical cross-linking and common pressure drying) for fabricating a bio-based foam material using pulp fibers sourced from discarded sugarcane bagasse and sodium alginate extracted from seaweed. The resulting foam material exhibits low density (13.7–20.5 kg/m3), exceptional thermal insulation properties (thermal conductivity as low as 38.6 mW/mK), thermal stability (no deformation at 140 °C), and mechanical strength. After a basic silane modification, it also shows favorable water resistance (with a contact angle of 128°). Moreover, the foam material demonstrates remarkable degradation performance, with a degradation rate exceeding 93.8 % after 90 days of burial in soil. Therefore, this novel method offers a sustainable solution for eco-friendly foam production across various application domains.

Cellulose-Based Acoustic Absorber with Macro-Controlled Properties

Cellulose-based materials are now commonly used, including in the field of acoustic comfort. Often presented as a less environmentally impactful alternative to traditional acoustic absorbents (such as melamine, glass wool, etc.), these cellulose-based materials are more frequently derived from recycling, undergoing, in most cases, a technical process that allows these cellulose fibers to be obtained, thus inheriting the acoustic properties of the latter, with limited or even non-existent control. This paper proposes a manufacturing process that allows for the production of cellulose foam with precise control over its porosity, pore size, and interconnections. In addition to exhibiting good sound absorption properties, this process also enables the fabrication of gradient-porous structures and other hybrid materials, which can result in remarkable sound absorption properties.

Properties evolutions during carbonization of carbon foam using lignin as sole precursor

Lignin has been proved to be a promising precursor for producing carbon foam. The thermal and chemistry properties of lignin during its thermal conversion make it quite unique comparing with other precursors, and the conversion parameters can clearly affect the properties of the derived products. Therefore, this study systematically investigated the effects of key carbonization parameters on the properties of the resulting carbon foam materials. The findings demonstrate that the performance of the self-shaping lignin-derived carbon foam is simultaneously influenced by the factors that carbonization temperature, heating rate, and carbonization duration. Specifically, the carbonization temperature and carbonization duration have a significant impact on the mechanical performance, where higher temperatures and long carbonization time improve compressive strength and specific strength. Moreover, the data revealed that elevated temperatures, rapid heating rates, and shortened carbonization periods collectively promoted the development of higher porosities and larger pore diameters within the carbon foam structure. Conversely, lower carbonization temperatures, slower heating rates, and extended carbonization durations facilitated the formation of microporous in the carbon foam. This study provides a scientific foundation for optimizing the production of lignin-derived carbon foam with tailored properties and performance characteristics.

A green synthesis strategy for liquid microcapsule flame-retardant polyurethane foam: Lowering consumer health risks from flame retardant inhalation and ensuring long-lasting fire safety

Dimethyl methylphosphonate (DMMP), is widely used in the production of commercial flexible polyurethane foam due to its excellent fire-retardant properties and the low addition levels required. However, in daily use, the volatility and migration of this liquid fire retardant reduce its fire safety performance and pose significant health risks. To address this issue, we employed interfacial polymerization facilitated by ultraviolet light-induced triallyl isocyanurate (TAIC) cross-linking at the water-oil interface to rapidly encapsulate DMMP. Incorporating TAIC@DMMP microcapsules into FPUF composites effectively suppressed DMMP emissions, maintaining low health and fire safety risks. These microcapsules act as sprinkler heads within each FPUF cell, rupturing during flame propagation. This release of phosphorus-containing radicals significantly enhances fire safety, reducing the peak heat release rate (PHRR) and total heat release (THR) by approximately 47% and 33%, respectively. The TAIC@DMMP microcapsule FPUF composite material exhibited excellent fire safety performance after 28 years of long-term aging simulated in an oven, passing the vertical burning test. In an environment simulating a 60 °C heat source, the TAIC@DMMP microcapsule FPUF composite material significantly reduced the release of DMMP, lowering the carcinogenic risk and non-carcinogenic risk by approximately 80 times and 100 times, respectively. This study presents a method for preparing FPUF composites that balance fire safety and environmental health, offering a valuable reference for further research on flame-retardant materials in environmental safety.

Investigations into the foaming behavior of ABS by means of granule extrusion using expandable microspheres

The following investigations address the production of syntactic polymer foams using thermally expanding microspheres (TEM) in the extrusion process. A process model for the foaming behavior of acrylnitrile butadiene styrene (ABS) with thermally expanding microspheres as masterbatch is derived by varying the two basic process parameters extruder rotational speed and extruder temperature in a test matrix with five stages each. The investigations include the production of unfoamed and foamed strands and the measurement of process relevant properties and parameters such as extrusion mass flow, relative density of the structures, die-swelling and the characterization of the generated foam structures. The achievable density reduction is within the order of 50%. The process model resulting from the investigations allows the production of homogeneously foamed strands. These results are intended to serve as the basis for a transfer to the Large Scale Additive Manufacturing (LSAM) process.

Fabrication of high performance polypropylene based blends from ethylene vinyl acetate-based sole waste via solid-state shear Co-milling

Ethylene vinyl acetate copolymer (EVA) foam products with cross-linked structure are now widely used in the fields of functional footwear. However, due to their cross-linked structure and complex composition, they are quite difficult to be recovered in large scale after disposal, causing serious environmental pollution. Based on our self-designed solid-state shear milling (S3M) equipment, a novel co-milling technology was established to recycle ethylene vinyl acetate-based sole waste (ESW) and reuse it to strengthen and toughen polypropylene (PP). The effects of co-milling on PP/ESW powders as well as blends were studied, and the results showed that the existence of PP promoted the solid pulverization of ESW, so formed the powders with smaller size and wider distribution. Ascribing to the partial de-crosslinking of ESW during co-milling process, the contact area and the molecular entanglements at their interfaces increased, effectively improving the compatibility between PP and ESW. In this way, the simultaneous enhancement and toughening of ESW on PP were achieved. After co-milling, ESW phase in blends significantly decreased and no visible phase interface was observed. With 20 co-milling cycles, the tensile strength and impact toughness of PP/20 wt% ESW blend respectively increased from 21.9 MPa to 3.79 kJ/m2 to 25.4 MPa and 5.83 kJ/m2, both higher than most other similar PP based materials. This work provides a new strategy for high-quality and efficient recycling of ESW in large scale, and fabrication of high-performance PP based materials.

Lightweight reticulated mullite foams of zero strut porosity from preceramic polymer resins

This study presents a novel approach for fabricating reticulated mullite and zirconia-mullite ceramic foams by using in-house synthesized preceramic polymers. Unlike traditional aqueous slurry methods, this technique employs polymeric resins, specifically aluminosiloxane (AS) and zirconoaluminosiloxane (ZAS), in a toluene medium. The process utilizes polyurethane (PU) foam template, with a two-time impregnation and squeezing method to ensure adequate resin loading. X-ray diffraction confirmed silica devitrification and vitrification at 1500°C and 1600°C, respectively, enhancing mullite densification. SEM imaging revealed the formation of nonporous struts and ligaments with needle-shaped grains and tetragonal zirconia nanocrystals at 1600°C. The foams demonstrated porosity between 83 and 95.2%, compressive strength from 0.44 to 0.11 MPa, and thermal conductivity from 0.15 to 0.08 W/mK. This research highlights the potential of using AS and ZAS resins for the production of high-performance ceramic foams, marking a significant innovation in the field.

A systematic review of methodologies and solutions for recycling polyurethane foams to safeguard the environment

Today, plastic plays a pervasive role in everyday life. Their improper disposal can create ongoing environmental challenges. Polyurethane (PU) is a polymer with elastomeric properties that exhibits significant adhesion and durability. PU has various colors and resistance to acid and alkali substances. The widespread use of PU has caused a significant presence of these compounds in landfills. Therefore, it can cause significant plastic pollution globally. This increased environmental concern has prompted researchers and innovators to explore sustainable methods for recycling PU foam. Therefore, the recycling of PU waste is recognized as an essential requirement due to its economic and environmental benefits. Although the latest reviews focused on physical, chemical, and biological methods of PU recycling, a comprehensive review of other PU recycling methods is needed. Therefore, the present study is a systematic review of recent initiatives and innovations in the field of recycling and modification of PU foam production methods to recognize and reduce environmental impacts. In the present study, major global databases such as Web of Science, PubMed, Scopus, Google Scholar, and Iranian databases (up to January 2024) were searched with relative keywords to identify studies published in authoritative journals. Data were collected from qualified articles on different PU recycling methods and innovative processes. From a total of 1088 articles found, finally, 46 studies met the objectives and inclusion criteria. Based on the results, today various methods are used to recycle PU compounds, but more attention has been paid to efficient methods such as energy production and high-consumption products such as rubber and adhesive from these compounds. In addition, it highlights some approaches, such as the production of absorbents from PU foams, which not only improve the current technology but also show promise in reducing the environmental impact of this ubiquitous material.

Optimizing Glass Foam Production from Recycled Sources: Influence of Variation in Cullet Color and Spent Alkaline Battery Components

Glass foams present a compelling opportunity for upcycling glass waste, offering a favorable combination of low weight, thermal insulation, and mechanical strength. Prior works demonstrated the feasibility of producing glass foams from glass waste and foaming agents sourced from synthetic textile waste, manganese oxides, and spent alkaline battery cathodes. This work explores the optimization of the process, investigating the impact of glass composition of differently colored glasses on final properties and incorporating entire alkaline batteries, encompassing both cathode and anode components. By carefully adjusting the composition, foaming agent content, and process temperature, customizable properties are achieved. Increasing foaming agent content or utilizing transparent glass improves insulation but lowers density and mechanical properties. Lowering foaming agent content or using brown/green glass enhances density and strength at the expense of insulation. Temperatures beyond 900 °C increase crystalline content, boosting mechanical performance without affecting density. This innovative approach not only offers a pathway to sustainable insulation materials but also underscores the potential for minimizing environmental impact through the efficient upcycling of glass waste.

Evaluation of critical process parameter on the production of sustainable bead foams based on polylactic acid

A commercial grade of polylactic acid (PLA) was foamed without using modifiers to obtain expanded polylactic acid bead foams (EPLA). Typically, the foaming process is influenced by both melt properties and crystallization behavior. While factors like water temperature, die structure, and die temperature are known to have effects on bead foam processing, these aspects have not been thoroughly explored in the context of PLA bead foam production. To address this gap, a comprehensive investigation was undertaken, varying water temperature, die structure, and die temperature to discern their impact on PLA processing behavior. Results revealed that water temperature significantly influenced foaming behavior, particularly at elevated temperatures near the glass transition of PLA. Additionally, the study demonstrated that die size wielded a notable influence on all foam properties, dictating process limits. With the selection of an appropriate die size, the die temperature could be manipulated within the range of 190°C to 160°C, revealing a substantial impact on the overall process. Remarkably, the lowest densities achieved were 63 kg/m3 with an average cell size of 36 µm and a cell density of 1.1*107 cells per cm3.

Utilization of Neem Seed Oil as Surfactant in the Production of Flexible and Rigid Polyurethane Foam

Extraction and processing of polyether polyols derived from petrochemicals, commonly used as surfactants during polyurethane foam (PUF) production, contribute to carbon emissions and raises the issue of long-term sustainability given that petrochemicals are non-renewable resources. Here, 5 mg and 4 mg of neem seed oil are employed to form flexible and rigid PUF, classified purposefully based on their divergent usage. To find an environmentally friendly replacement, flexible PUF whose mass, volume, density, compression, tensile strength, cream time, foam rise and rising time are 0.0047 kg m3, 16.52 kg/m3, 8.10%, 39.28 kN/m2, 60s, 10s and 60s is formed by mixing 1.25 kg polyol, 5mg silicon oil and 10g calcium carbonate (CaCO3). Likewise, by mixing 1.2 kg polyol, 4mg silicon oil and 8g CaCO3, a rigid PUF with 0.005kg, m3, 16.2 kg/m3, 8.15%, 40.72 kN/m2, 50s, 15 cm and 58s key, physical and mechanical property as respectively listed under the flexible PUF formulation is produced. Both foams were produced using equal amounts of toluene diisocyanate, water, stannous octoate and methylene chloride, resulting in PUF that can be used in insulation, cushioning and construction support applications based on their characteristic height, density, tensile strength and compressive strength. As the surfactant, neem seed oil's potential in the synthesis of PUF cannot be overemphasized. The study of the kinetics of PUF production is limited and should trigger the adoption of biobased surfactants for industrial applications in the future.

A statistical approach towards determining the governing parameters in volume expansion behavior of polypropylene foams

This study delves into the complex relationship between molecular structures and properties within polypropylene (PP) foams, with a particular focus on how various material parameters influence foamability. Multiple linear regression was adopted to efficiently assess the impact of eleven material parameters on foam expansion behavior. A primary finding is the significant role of branching index (g'vis) in shaping the expansion profile (i.e., the foaming window, maximum expansion ratio (Φmax), and optimum foaming temperature (Toptimum)). Additionally, Z-average molecular weight (Mz) is identified as crucial factor influencing the foaming window. Furthermore, the Winter-Chambon parameter n, indicator of the relaxation behavior of a resin in the terminal zone, is distinguished as a key parameter in determining Φmax. The crystallization temperature (Tc) also plays a pivotal role, particularly in its relationship with Toptimum. The research further highlights the significance of long-chain branching (LCB) and suggests strategies for cost reduction by minimizing the degree of LCB without compromising foaming performance, achievable through the adjustment of Mz and n. This strategy was exemplified through the comparison of two LCB PP resins, PP-12 and PP-22, demonstrating the feasibility of achieving similar foamability with adjustments in material parameters. The findings offer a detailed assessment of these parameters' influence on foamability, presenting valuable guidelines for optimizing PP foam production and customizing material properties for targeted applications.

Environmental benefits of valorising food waste into bio-based polyols for the production of polyurethane rigid foams

Under the global pursuit of sustainable development, waste streams are being recognised as renewable feedstocks to produce value-added products. Given this, food waste (FW) was explored to synthesise bio-based polyols to further develop polyurethane rigid foams (PURF). However, relevant environmental aspects are yet to be examined to support this biorefinery scheme as a green and sustainable solution. In this work, we examined the environmental performance associated with the production of PURF using polyols derived from a FW biorefinery scheme by life cycle assessment (LCA). Analysis was first conducted at the polyol level. Different allocation and offset options were examined to configure the LCA model. Based on mass allocation, compared with fossil-based production, the production of FW-derived polyols achieved reductions of 24.30 % and 34.19 % in global warming potential (GWP) and cumulative energy demand (CED), respectively. At the midpoint level, FW-derived polyols had reduced impacts on human carcinogenic toxicity, freshwater eutrophication, and fossil resource scarcity but caused additional burdens on freshwater and marine ecotoxicity. Key environmental hotspots at this level included diethylene glycol, ion exchange resin (epoxidation catalyst), and hydrogen peroxide. The lipid content in FW also played a significant role. It was demonstrated that reducing the use of enzymes for FW hydrolysis to a cost-effective level remarkably mitigated the overall impacts of FW-derived polyol production. At the next level, we examined the production of FW-derived PURF using the obtained polyols. When 70 % of the polyols were replaced with bio-based products, the resultant PURF production achieved a GWP and CED of 5.67 kg CO2eq and 110.66 MJ/kg, respectively. In general, FW-derived PURF leads to environmental benefits compared to fossil-based ones. However, isocyanate used for foam formulation was the dominant contributor, causing almost two-thirds of the total impacts. The flame retardant also caused considerable impacts. Through the systematic examination of FW-derived polyols and PURF, this study demonstrated that FW-derived PURF could benefit the sustainable development of FW biorefineries and bio-based plastic industries, while the identified environmental hotspots need to be further studied and replaced with greener substitutes.

Waste-to-resource: Employing lime mud as a foaming agent in glass foam manufacturing

The paper industry globally releases vast amounts of lime mud waste annually, raising environmental concerns. Composed mainly of calcium carbonate, lime mud has been utilized in various research works, including catalyst synthesis, cement production, and ceramic fabrication. This study investigates the use of lime mud as an eco-friendly foaming additive in the production of glass foam. Glass foams were prepared through a simple sintering method, utilizing glass cullet collected from households and incorporating different lime mud contents (0.5–2.0 wt%). The effects of lime mud concentration on the density, porosity, and pore size distribution of the glass foams were examined. Additionally, the thermal conductivity, compressive strength, and Weibull modulus were investigated in relation to the average porosity. The results revealed that the pore size distribution was dependent on the amount of lime mud, exhibiting three distinct distributions: a positively skewed distribution, a non-symmetric bimodal distribution, and a positively skewed distribution with a wide range. The Weibull modulus markedly decreased with increasing pore size. The compressive strength of the prepared glass foams ranged from 5.53±0.40–12.73±0.46 MPa, while the bulk density and porosity fell within the ranges of 0.41±0.02–0.70±0.04 g/cm3 and 72.12±1.45–85.38±0.98 %, respectively. The thermal conductivity could be as low as 0.07 W/m·K, approaching the upper limit for commercial glass foams used in thermal energy storage systems and meeting the requirements for Type I cellular glass thermal insulation classified by ASTM C552–16.

Unlocking the potential of functionalized cottonseed oil for the production of biobased epoxy foams

Nowadays, polymer foams are present in various areas of modern life. Having valuable and versatile features, they are utilized for insulation, packaging, sound absorption, cushioning and many other applications. Most of the commercially available polymer foams, whether rigid or flexible, are made from petrochemicals. Among these porous polymers, polyurethanes derived from highly hazardous isocyanates are dominant. Replacement of such foams with more environmentally safe materials holds great significance in the context of sustainability policy. Therefore, the utilization of molecules derived from biomass for the production of porous polymer foams is of considerable importance. This work focuses on the development of thermoset flexible foams based on plant oil, namely cottonseed oil. The polymeric matrix of the foams was prepared by the reaction of epoxidized cottonseed oil (ECO) with a cyclic anhydride in the presence of a catalyst, whereas the gaseous phase was generated by the addition of a chemical blowing agent. The morphology of the prepared foams was characterized using Scanning Electron Microscopy, while the internal structure of the foams was studied via Micro-Computed Tomography. The thermomechanical properties of foams were evaluated by Thermogravimetric Analysis (TGA), Differential Scanning Calorimetry (DSC) and Dynamic Mechanical Analysis (DMA). Possessing flexibility, softness, high porosity and shape memory ability, the prepared foams can be considered as potential cost-effective and eco-friendly options for flexible foams market: furniture, carper underlay, bedding.

Waste-to-energy: Repurposing flexible polyurethane waste for triboelectric nanogenerator applications

Triboelectric Nanogenerators (TENG) is a promising approach for clean energy harvesting. Light weight, flexible, cheap and environmentally-friendly materials are being explored as potential components in the TENG device in order to increase its efficiency. This paper reports the first effort to successfully utilize rebonded flexible polyurethane (RFPU) waste as a tribopositive material in a TENG device. A batch moulding technique was used to create two different densities (60 and 70 kg/m3) of flexible polyurethane (FPU) scraps, including customer waste and slabstock foam production waste. The current study investigates the effect of density on the compression strengths of the RFPU materials, as well as the impact on the output voltage of the TENG. Additionally, the effect of various RFPU sheet thicknesses (2, 4, 6, and 8 mm) as well as the effect of different applied forces and frequencies on the TENG's output voltage were investigated. The findings showed that the compressive strength increases with higher RFPU density. The output voltage values of the TENG device were recorded both with and without pre-charging. The results, without pre-charging, revealed that the highest output voltage of the TENG was obtained using an RFPU sheet with a density of 60 kg/m3. Furthermore, output voltage was shown to decrease with increasing RFPU sheet thickness and to increase with applied frequency. Pre-charging showed a similar trend, but yielded better results compared to the RFPU samples that were not pre-charged. The power density peaked at 0.085 mW/cm2, at a load resistance of 5 MΩ and a force of 4.7 N. The RFPU-based TENG successfully powered four white LEDs connected in series. Analysis of the embodied energy associated with using PU foam waste instead of virgin PU foam was conducted and demonstrated that utilizing PU foam waste provides environmental benefits due to the significant contribution of raw materials to the overall embodied energy in PU foam that is saved when reusing foam waste. Additionally, assessing the embodied energy of the components of the TENG device was also conducted and shows that the generated energy can partially offset the embodied energy of the TENG device. As a result, the prepared RFPU material not only helps to safeguard the environment but also shows great promise for use in developing more efficient and affordable TENGs in the future.

Vanillic acid-based pro-coagulant hemostatic shape memory polymer foams with antimicrobial properties against drug-resistant bacteria

Uncontrolled bleeding is the primary cause of trauma-related death. For patients that are brought to the hospital in time to receive treatment, there is a great risk of contracting drug-resistant bacterial wound infections. Therefore, low-cost hemostatic agents with procoagulant and antibacterial properties are essential to reduce morbidity and mortality in patients with traumatic wounds. To that end, we introduced vanillic acid (VA) into shape memory polymer (SMP) foams through a dual incorporation mechanism to make dual vanillic acid (DVA) foams. The dual mechanism increases VA loading while allowing burst and sustained delivery of VA from foams. DVA foams exhibit antimicrobial and antibiofilm properties against native and drug-resistant Staphylococcus aureus (S. aureus) and Staphylococcus epidermidis. Also, DVA foams inhibit the growth rate of both methicillin-sensitive and -resistant S. aureus colonies to limit their size and promote small colony variants. DVA SMP foams induced primary and secondary hemostasis in in vitro blood interaction studies. As a proof of concept, we demonstrated easy delivery and rapid clotting in a porcine liver injury model, indicating DVA foam feasibility for use as a hemostatic dressing. Thus, the inexpensive production of DVA SMP foams could enable a cost-effective procoagulant hemostatic dressing that is resistant to bacterial colonization to improve short- and long-term outcomes for hemorrhage control in traumatically injured patients. Statement of significanceUncontrolled bleeding is the primary cause of preventable death on the battlefield. Of patients that survive, ∼40 % develop polymicrobial infections within 5 days of injury. Drug-resistant infections are anticipated to cause more deaths than all cancers combined by 2050. Therefore, novel non-drug-based biomaterials strategies for infection control in wound care are increasingly important. To that end, we developed hemostatic polyurethane foams that include antimicrobial and pro-coagulant vanillic acid, a plant-based antimicrobial species. These foams provide excellent protection against native and drug-resistant bacteria and enhanced coagulation while remaining cytocompatible. In a pilot porcine liver injury model, vanillic acid-containing foams stabilized a bleed within <5 min. These biomaterials provide a promising solution for both hemorrhage and infection control in wound care.