About Compofoam

COMPOFOAM has developed a unique technology to produce massively muliti-metal sandwich (MMS) and aluminum foam sandwich (AFS)

Technologies have been developed and tested during almost 15 years of R&D in the laboratory of the CNRC in Boucherville (Qc, from 2001 to 2009) and the pilot plant (2009 to 2015) and has required close to $9.5MM in investment

MMS and AFS represents a new class of sustainable, low cost, lightweight and high strength structural materials.




Mr. Serguei Vatchiants, an inventor and businessman, has developed an innovative and unique technology for the manufacturing of engineering aluminum foam composites with programmed properties and considerably lower production cost in comparison with competitors in the field.

Today the technology allows for production of structural materials with programmed and well-controlled properties, variable densities and reinforced by different metals, chemical or ceramic elements for high rigidity and compression resistance. Panels have strong metallurgical bonding between the foam and cladding material (titanium, stainless or carbon steel). It can also be a sandwich with dense natural aluminum surfaces produced by using a special technique of powder preparation. The process can be applied for production of 3D objects.

The technology has been validated not only in the laboratory, but also on a pre-commercial pilot scale unit at a National Research Council of Canada as well as at the current location of the pilot plant in Saint-Laurent (Montreal). Steps to protect the innovation within its portfolio of intellectual property have been taken in the USA and the participating countries in the Euro patent zone. One patent has been issued in both the US and Europe. Another a new patent application Mr. Vatchiants finished, will be revealed this year.


Mr. Vatchiants has been involved in several projects during the last 25 years. But his main objective during the last 20 years has been the development of aluminum foam production technology. For that purpose, in 1996 Serguei Vatchiants opened a company which was specifically focused on the development of the processes for aluminum foam production and R&D work. Compofoam Inc. will carry out the next phase of the project, which is the commercialization of the technology and the construction of a full-scale 1220x2440mm (4’x8’) cladded panel manufacturing facilities in Canada and the USA. An R&D activity may remain for application development for the market development.

Mr. Serguei Vatchiants,  President and Chief Executive Officer Compofoam Inc., will keep his leading role in COMPOFOAM Inc. to bring the aluminum foam project to its completion and to form the business strategy of the new company.


Mr. Vatchiants holds a master’s degree of Science in Civil and Metallurgical Engineering. For the last 20 years, he has been actively developing aluminum foam production processes. His blend of skills allows him to understand the product development process from both the manufacturing/technical perspective and the business/marketing perspective. He has had extensive experience in international markets including Eastern and Western Europe, Russia, Iran, and Algeria. Mr. Vatchiants has taken his company from the initial conception of the technology, through the research and development stage and product trials, negotiating strategic alliances, raising capital, and promoting products in the marketplace.

Mission Statement

The mission of Compofoam is to be recognized worldwide as a leader in the manufacture and supply of sustainable, ultra-light, economical structural materials and in the development of new applications.

Why Compofoam products are sustainable and responsible?

  • The aluminum core is made from aluminum scrap
  • Products can be lighter (because a higher stiffness to weight ratio) than material common material used  for same stiffness (ex.: 3 times that of aluminum, and 5 times lighter than steel)
  • Lighter during movement means lower energy consumption
  • Process doesn’t produce gas emission (compared to some industries that they are using solvent or a lot of fossil energy to transform material)
  • Only hydroelectricity is using during the process
  • Products can be recyclable

What is new and innovative?

Production of Precursor Material (prior to foaming) using both patented and proprietary methods that:

  • Achieves composite product with metallurgical  bonding between the compacted formulated powder and the cladding material (aluminum, carbon steel, stainless steel, and titanium).
  • Produce large size panels – up to 4 x 8 ft and thicknesses (a range of 5 – 60 mm  was achieved during testing). Readily weldable to form any requirement.
  • Provides for preforming complex shapes prior to foaming.
  • Provides flexibility to manufacture customized composite products, including un-foamed composite sheets; multilayer composites (combination of dense and foamed layers); and reinforcement of aluminum foam cores with special materials
  • Foaming Process employs both patented and proprietary methods that:
      • Enable high volume production
      • Allow for strict quality control of pore size and foam density
      • Utilize energy efficient induction heating process