Liquid foam templating - A route to tailor-made polymer foams

Amphiphilic Janus Particles for Aerobic Alcohol Oxidation in Oil Foams

Amphiphilic Janus silica particles, tunable with oleophobic-oleophilic properties and low fluorine content (8 wt % F), exhibited prominent foamability for a variety of aromatic alcohols at low particle concentrations (<1 wt %) compared to randomly functionalized silica particles. When selectively loaded with Pd nanoparticles on the oleophilic hemisphere, the particles displayed more than a 2-fold increase in catalytic activity for the aerobic oxidation of benzyl alcohol compared to nonfoam bulk catalysis under ambient O2 pressure. The particles were conveniently recycled with high foamability and catalytic activity maintained for at least five consecutive runs.

Solidification of Polyurethane Model Foams via Catalyst Drainage from a Secondary Foam

Due to their unique mechanical and thermal properties, polyurethane foams are widely used in multiple fields of applications, including cushioning, thermal insulation or biomedical engineering. However, the way polyurethane foams are usually manufactured - via chemical foaming - produces samples where blowing and gelling occur at the same time, resulting in a morphology control achieved by trial and error processes. Here, a novel strategy is introduced to build model homogeneous polyurethane foams of controlled density with millimetric bubbles from liquid templates. By producing a polyurethane foam via physical bubbling without a catalyst and gently depositing a secondary foam containing catalyst on the top of this first foam, it is possible to take advantage of drainage mechanisms to trigger the solidification of the bottom foam. The characterization of the samples performed by X-ray microtomography allows to study quantitatively the structure of the final solid foam, at the global and at the local scale. Using the tomographic 3D images of the foam architectures, the superimposed foam technique introduced in this article is shown to be promising to produce foams with a good homogeneity along the vertical direction, with a density controlled by varying the concentration of catalyst in the secondary foam.

Liquid foams: Properties, structures, prevailing phenomena and their applications in chemical/biochemical processes

Liquid foams are gas-liquid dispersions with flexible structures that provide high gas-liquid interfaces. This property nominates liquid foams as excellent gas-liquid contactors, systems that are widely used in the chemical and biochemical industries. However, challenges such as a lack of comprehensive understanding and foam instability have historically hindered their widespread industrial use in most applications. It was not until the recent development of nanofluidics, nanotechnology, surface science, and other related fields that the understanding, analysis, and control of foam phenomena improved. This led to the development of innovative stabilization techniques and foam-based unit operations in chemical and biochemical processes, each of which requires in-depth and exclusive reviews to fully comprehend their potential and limitations and to identify areas for further improvement and innovation. This paper reviews the foams, the common phenomena in them, the characteristics that make them suitable for chemical/biochemical engineering, reports on their current applications and recent developments in this field.

Porous superabsorbent composites prepared from aqueous foam template and application evaluation

Rapid water absorption is very important for the application of superabsorbent polymers under dry or semi-dry conditions, but there are currently few relevant studies. In this context, a novel porous superabsorbent of chitosan-grafted acrylic copolymer-2-acrylamido-2-methylpropanesulfonic acid/sapindus mukorossi pericarp/calcined oil shale semi-coke (CS-g-P(AA-co-AMPS)/SMP/COSSC) was prepared by a green and convenient foam template method, which was triggered by redox polymerization. The rich pore structure of the porous superabsorbent was conducive to accelerating the water absorption rate. It only took 15 min to reach a swelling capacity of 650 g g-1 in distilled water. Soil experiments show that even with the addition of 0.5 wt% porous superabsorbent, the soil water retention time can be extended to 7 days. Finally, it was applied to the growth of cabbage seeds and it was found that the growth was significantly improved. Based on these excellent properties, we expect to provide a valuable reference for the preparation of fast-absorbing materials through the green water-based foam template method, contributing to sustainable agriculture.

Tetrahedron clusters serving as a platform for foam-like structure design

There are a number of exceptional examples indicating the unique position of tetrahedral symmetry in the vast landscape of different spatial organization pathways which can be sampled by matter. This work shows that the design and analysis of relatively simple tetrahedron clusters can lead to the formulation of a new type of dendritic structure together with unique periodic frameworks resembling clathrates and foams. A simple sequential protocol leading from regular tetrahedron clusters to more complex structural motifs can be employed to determine interesting repetitive building units. Accordingly, four different hierarchical superstructures are introduced, in which the dominant population of nodes is based on tetrahedral symmetry. The introduced architectures could be of particular interest for the field of regenerative medicine and metamaterial engineering.

A unifying Rayleigh-Plesset-type equation for bubbles in viscoelastic media

Understanding the ultrasound pressure-driven dynamics of microbubbles confined in viscoelastic materials is relevant for multiple biomedical applications, ranging from contrast-enhanced ultrasound imaging to ultrasound-assisted drug delivery. The volumetric oscillations of spherical bubbles are analyzed using the Rayleigh-Plesset equation, which describes the conservation of mass and momentum in the surrounding medium. Several studies have considered an extension of the Rayleigh-Plesset equation for bubbles embedded into viscoelastic media, but these are restricted to a particular choice of constitutive model and/or to small deformations. Here, we derive a unifying equation applicable to bubbles in viscoelastic media with arbitrary complex moduli and that can account for large bubble deformations. To derive this equation, we borrow concepts from finite-strain theory. We validate our approach by comparing the result of our model to previously published results and extend it to show how microbubbles behave in arbitrary viscoelastic materials. In particular, we use our viscoelastic Rayleigh-Plesset model to compute the bubble dynamics in benchmarked viscoelastic liquids and solids.

Construction of high-branched derivatives based on melamine for highly effective defoaming and antifoaming

Foams can be seen everywhere in human production and life. An uncontrolled foam event usually leads to product losses, equipment damage, and clean-up costs. Defoamer is one of the most effective strategies to eliminate or inhibit foam activities, which has been proved by long-term practices. In this work, we report new molecular defoamers with high-branched structure, which adopts melamine molecule as the parent structure, by incorporating alkyl-isocyanates with different chain lengths into the high-branched melamine derivatives (Hb-MDs) formula to replace the R - NH2 (primary ammonia) on melamine structure. The substitution reaction processes can be readily tuned by varying the molar ratio or alkyl chain length of alkyl-isocyanate, enabling a facile control over the branched degree. The foam tests reveal that the high-branched melamine molecule defoamers exhibited excellent defoaming and anti-foaming properties for four typical foam systems, including an anionic SDBS, cationic DTAB, non-ionic AEO-9, and white cat (BM) detergent, with efficiency close to that of silicone-type LN1414 defoamer and far superior to that of high-carbon alcohol XS-02 defoamer, at the same addition level. Notably, the defoaming or anti-foaming performances of the high-branched melamine molecule defoamers were not always monotonically increased with the branched degree or hydrophobic chain length, but a suitable range needed to be maintained to support a good balance of defoamer structure with foam liquid films. Therefore, it is anticipated that this high-branched design principle could open a new avenue for the construction of molecular defoamers for complex industrial problems.

Fabrication porous adsorbents templated from aqueous foams using astragalus membranaceus and attapulgite as stabilizer for efficient removal of cationic dyes

The water-based foam stabilized by the natural surfactant applied in the fabrication of porous materials has attracted extensive attention, as the advantages of cleanness, convenience and low cost. Particularly, the development of a green preparation method has became the main research focus and frontier. In this work, a green liquid foam with high stability was prepared by synergistic stabilization of natural plant astragalus membranaceus (AMS) and attapulgite (APT), and then a novel porous material with sufficient hierarchical pore structure was templated from the foam via a simple free radical polymerization of acrylamide (AM). The characterization results revealed that the amphiphilic molecules from AMS adsorbed onto the water-air interface and formed a protective shell to prevent the bubble breakup, and APT gathered in the plateau border and formed a three-dimensional network structure, which greatly slowed down the drainage rate. The porous material polyacrylamide/astragalus membranaceus/attapulgite (PAM/AMS/APT) showed the excellent adsorption performance for cationic dyes of Methyl Violet (MV) and Methylene Blue (MB) in water, and the maximum adsorption capacity could reach to 709.13 and 703.30 mg/g, respectively. Furthermore, the polymer material enabled to regenerate and cycle via a convenient calcination process, and the adsorption capacity was still higher than 200 mg/g after five cycles. In short, this research provided a new idea for the green preparation of porous materials and the treatment of water pollution.

Relation between oxidation kinetics and reactant transport in an aqueous foam

HYPOTHESIS

Aqueous foams are expected to constitute exquisite particularly suitable reactive medium for the oxidation of metals, since the reactant H⁺ can be supplied through the continuous liquid phase, while the reactant O₂ can be transported through the gas bubbles.

EXPERIMENTS

To test this hypothesis, we investigated the oxidation of a metallic copper cylinder immersed in an aqueous foam. To study the relation between the transport of these reactants and the kinetics of the chemical reaction we use a forced drainage setup which enables us to control both the advection velocity of the H⁺ ions through the foam and the foam liquid fraction.

FINDINGS

We find experimentally that the mass of dissolved copper presents a maximum with the drainage flow rate, and thus with the foam liquid fraction. Modeling analytically the transfer of H⁺ and O₂ through the foams enables us to show that this non-monotonic behavior results from a competition between the advective flux of H⁺ ions and the unsteady diffusion of O₂ through the thin liquid films which tends to be slower as the area of the thin liquid films decreases with the drainage flow rate and the liquid fraction. This study shows for the first time how to optimize the foam structure and drainage flow in reactive foams in which the reactants are present both in the liquid and gaseous phases.

Porous Hydrogels: Present Challenges and Future Opportunities

In this feature article, we critically review the physical properties of porous hydrogels and their production methods. Our main focus is nondense hydrogels that have physical pores besides the space available between adjacent cross-links in the polymer network. After reviewing theories on the kinetics of swelling, equilibrium swelling, the structure-stiffness relationship, and solute diffusion in dense hydrogels, we propose future directions to develop models for porous hydrogels. The aim is to show how porous hydrogels can be designed and produced for studies leading to the modeling of physical properties. Additionally, different methods that are used for making hydrogels with physically incorporated pores are briefly reviewed while discussing the potentials, challenges, and future directions for each method. Among kinetic methods, we discuss bubble generation approaches including reactions, gas injection, phase separation, electrospinning, and freeze-drying. Templating approaches discussed are solid-phase, self-assembled amphiphiles, emulsion, and foam methods.

Density graded polymer composite foams

This article reviews the main developments associated with density graded polymer composite foams. After a short introduction, a discussion is made on both density graded polymer-based composites and foams separately to better understand the challenges when both structures are combined together to produce composite foams. In all cases, the basic concepts, fabrication methods, main properties and general applications are presented. Opening for future works are also presented to conclude.

Biodegradable floating hydrogel baits as larvicide delivery systems against mosquitoes

Biological methods for mosquito larvae control are completely biodegradable and have null or limited effects on nontarget organisms. However, commercially available products have a low residual activity, with the consequent need for multiple applications that inevitably increase costs and the risk of resistance phenomena insurgence. Smart delivery systems made of hydrogels proved their efficacy in increasing the action duration of biolarvicides up to several months, but the lack of an efficient baiting mechanism to strongly attract the target pest remains a problem in practical applications. In this work, we investigated two novel hydrogel-based formulations of completely natural composition for baiting and killing larvae of Aedes albopictus mosquitos. The proposed materials consist of charged crosslinked polysaccharides (chitosan and cellulose) and are specifically manufactured to float in water, simulating organic matter usually present at breeding sites. Within the hydrogels' matrix, yeast colonies of Saccharomyces cerevisiae were embedded as phagostimulants alongside a biolarvicide (Bacillus thuringiensis var. israelensis (Bti)). Despite the similar chemical nature and structure, chitosan-based hydrogels exhibited a markedly superior baiting potential compared to those made of cellulose and also succeeded in efficiently killing mosquito larvae just after a few hours from administration. We are confident that the proposed smart delivery hydrogel made of chitosan can be an enabling tool to attract mosquito larvae towards biopesticides of different nature without delocalizing active ingredients away from the breeding site and to simultaneously increase their residual activity, thus holding the potential of minimizing environmental pollution related to pest control and vector-borne disease prevention.

One-Step Generation of Alginate-Based Hydrogel Foams Using CO2 for Simultaneous Foaming and Gelation

The reliable generation of hydrogel foams remains a challenge in a wide range of sectors, including food, cosmetic, agricultural, and medical applications. Using the example of calcium alginate foams, we introduce a novel foam generation method that uses CO₂ for the simultaneous foaming and pH reduction of the alginate solution to trigger gelation. We show that gelled foams of different gas fractions can be generated in a simple one-step process. We macroscopically follow the acidification using a pH-responsive indicator and investigate the role of CO₂ in foam ageing via foam stability measurements. Finally, we demonstrate the utility of interfacial rheology to provide evidence for the gelation process initiated by the dissolution of the CO₂ from the dispersed phase. Both approaches, gas-initiated gelation and interfacial rheology for its characterization, can be readily transferred to other types of gases and formulations.

Gelatin-based cellular solids: Fabrication, structure and properties

Although most cellular polymers are made from thermoplastics using different foaming technologies, gelatin and many other natural polymers can form hydrogels and convert them to cellular solids using various techniques, many of which differ from traditional plastic foaming, and so does their resulting structures. Cellular solids from natural hydrogels are porous materials that often exhibit a combination of desirable properties, including high specific surface area, biochemical activity, as well as thermal and acoustic insulation properties. Among natural hydrogels, gelatin-based porous materials are widely explored due to their availability, biocompatibility, biodegradability and relatively low cost. In addition, gelatin-based cellular solids have outstanding properties and are currently subject to increasing scientific research due to their potential in many applications, such as biocompatible cellular materials or biofoams to facilitate waste treatment. This article aims at providing a comprehensive review of gelatin cellular solids processing and their processing-properties-structure relationship. The fabrication techniques covered include aerogels production, mechanical foaming, blowing agents use, 3D printing, electrospinning and particle leaching methods. It is hoped that the assessment of their characteristics provides compiled information and guidance for selecting techniques and optimization of processing conditions to control material structure and properties to meet the needs of the finished products.

PoreScript: Semi-automated pore size algorithm for scaffold characterization

The scaffold pore size influences many critical physical aspects of tissue engineering, including tissue infiltration, biodegradation rate, and mechanical properties. Manual measurements of pore sizes from scanning electron micrographs using ImageJ/FIJI are commonly used to characterize scaffolds, but these methods are both time-consuming and subject to user bias. Current semi-automated analysis tools are limited by a lack of accessibility or limited sample size in their verification process. The work here describes the development of a new MATLAB algorithm, PoreScript, to address these limitations. The algorithm was verified using three common scaffold fabrication methods (e.g., salt leaching, gas foaming, emulsion templating) with varying pore sizes and shapes to demonstrate the versatility of this new tool. Our results demonstrate that the pore size characterization using PoreScript is comparable to manual pore size measurements. The PoreScript algorithm was further evaluated to determine the effect of user-input and image parameters (relative image magnification, pixel intensity threshold, and pore structure). Overall, this work validates the accuracy of the PoreScript algorithm across several fabrication methods and provides user-guidance for semi-automated image analysis and increased throughput of scaffold characterization.

•

PoreScript is a semi-automated MATLAB algorithm to rapidly and accurately characterize scaffold pore size distribution.

•

PoreScript was validated with multiple polymeric scaffolds of different fabrication methods and pore architectures.

•

Guidance of key input variables provides users with a tool for rapid characterization to accelerate scaffold development.

Investigating pore-opening in hydrogel foams at the scale of free-standing thin films

Controlling the pore connectivity of polymer foams is key for most of their applications, ranging from liquid uptake, mechanics, and acoustic/thermal insulation to tissue engineering. Despite its importance, the scientific phenomena governing the pore-opening processes remain poorly understood, requiring tedious trial-and-error procedures for property optimisation. This lack of understanding is partly explained by the high complexity of the different interrelated, multi-scale processes which take place as the foam transforms from an initially fluid foam into a solid foam. To progress in this field, we take inspiration from long-standing research on liquid foams and thin films to develop model experiments in a microfluidic "Thin Film Pressure Balance". These experiments allow us to investigate isolated thin films under well-controlled environmental conditions reproducing those arising within a foam undergoing cross-linking and drying. Using the example of alginate hydrogel films, we correlate the evolution of isolated thin films undergoing gelation and drying with the evolution of the rheological properties of the same alginate solution in bulk. We introduce the overall approach and use a first set of results to propose a starting point for the phenomenological description of the different types of pore-opening processes and the classification of the resulting pore-opening types. This article is protected by copyright. All rights reserved.

Smart ultra-stable foams stabilized using cellulose nanocrystal (CNC) gels via noncovalent bonding

Smart ultra-stable foams stabilized by cellulose nanocrystal (CNC)-based gels were fabricated. The stabilization is ascribed to the dense films and three-dimensional networks at the interface and in the bulk induced by the charge shielding effect and electrostatic attraction between protonated bis(2-hydroxyethyl)oleylamine (BOA-H⁺) micelles and negatively charged CNC colloids. The as-prepared foam could maintain its morphology without breaking or drainage for two months, showing high stability. Outstanding CO₂/N₂ reversibility endows the system with on-demand control of foaming/defoaming, which is necessary in many aspects. The functionalized foam is expected to open up an opportunity for the design of intelligent oilfield chemicals and extinguishant systems.

Macroporous Silica Foams Fabricated via Soft Colloid Templating

Macroporous materials with controlled pore sizes are of high scientific and technological interest, due to their low specific weight, as well as unique acoustic, thermal, or optical properties. Solid foams made of titania, silica, or silicon, as representative materials, have been previously obtained with several hundred nanometer pore sizes, by using sacrificial templates such as spherical emulsion droplets or colloidal particles. Macroporous structures in particular are excellent candidates as photonic materials with applications in structural coloration and photonic bandgap devices. However, whereas using spherical building blocks as templates may provide tight control over pore shape and size, it results in materials with an often unfavorable local topology. Templating dry-foam or compressed-emulsion structures appear as attractive alternatives, but have not been demonstrated so far for submicron pore sizes. Herein, the use of soft, flexible microgel colloids decorated with silica nanoparticles as templates of macroporous foams is reported. These purposely synthesized core-shell colloids are assembled at ultra-high effective volume fractions by centrifuging and thermal swelling, thereby resulting in uniform disordered materials with facetted pores, mimicking dry foams. After removal of the polymer component via calcination, lightweight pure silica structures are obtained with a well-defined cellular or network topology.

Advances in microfluidic 3D cell culture for preclinical drug development

Drug development is often a very long, costly, and risky process due to the lack of reliability in the preclinical studies. Traditional current preclinical models, mostly based on 2D cell culture and animal testing, are not full representatives of the complex in vivo microenvironments and often fail. In order to reduce the enormous costs, both financial and general well-being, a more predictive preclinical model is needed. In this chapter, we review recent advances in microfluidic 3D cell culture showing how its development has allowed the introduction of in vitro microphysiological systems, laying the foundation for organ-on-a-chip technology. These findings provide the basis for numerous preclinical drug discovery assays, which raise the possibility of using micro-engineered systems as emerging alternatives to traditional models, based on 2D cell culture and animals.

Microfluidics-Enabled Soft Manufacture of Materials with Tailorable Wettability

Microfluidics and wettability are interrelated and mutually reinforcing fields, experiencing synergistic growth. Surface wettability is paramount in regulating microfluidic flows for processing and manipulating fluids at the microscale. Microfluidics, in turn, has emerged as a versatile platform for tailoring the wettability of materials. We present a critical review on the microfluidics-enabled soft manufacture (MESM) of materials with well-controlled wettability and their multidisciplinary applications. Microfluidics provides a variety of liquid templates for engineering materials with exquisite composition and morphology, laying the foundation for precisely controlling the wettability. Depending on the degree of ordering, liquid templates are divided into individual droplets, one-dimensional (1D) arrays, and two-dimensional (2D) or three-dimensional (3D) assemblies for the modular fabrication of microparticles, microfibers, and monolithic porous materials, respectively. Future exploration of MESM will enrich the diversity of chemical composition and physical structure for wettability control and thus markedly broaden the application horizons across engineering, physics, chemistry, biology, and medicine. This review aims to systematize this emerging yet robust technology, with the hope of aiding the realization of its full potential.

Fundamentals and Design-Led Synthesis of Emulsion-Templated Porous Materials for Environmental Applications

Emulsion templating is at the forefront of producing a wide array of porous materials that offers interconnected porous structure, easy permeability, homogeneous flow-through, high diffusion rates, convective mass transfer, and direct accessibility to interact with atoms/ions/molecules throughout the exterior and interior of the bulk. These interesting features together with easily available ingredients, facile preparation methods, flexible pore-size tuning protocols, controlled surface modification strategies, good physicochemical and dimensional stability, lightweight, convenient processing and subsequent recovery, superior pollutants remediation/monitoring performance, and decent recyclability underscore the benchmark potential of the emulsion-templated porous materials in large-scale practical environmental applications. To this end, many research breakthroughs in emulsion templating technique witnessed by the recent achievements have been widely unfolded and currently being extensively explored to address many of the environmental challenges. Taking into account the burgeoning progress of the emulsion-templated porous materials in the environmental field, this review article provides a conceptual overview of emulsions and emulsion templating technique, sums up the general procedures to design and fabricate many state-of-the-art emulsion-templated porous materials, and presents a critical overview of their marked momentum in adsorption, separation, disinfection, catalysis/degradation, capture, and sensing of the inorganic, organic and biological contaminants in water and air.

Hydrogel foams from liquid foam templates: Properties and optimisation

Hydrogel foams are an important sub-class of macroporous hydrogels. They are commonly obtained by integrating closely-packed gas bubbles of 10-1000 μm into a continuous hydrogel network, leading to gas volume fractions of more than 70% in the wet state and close to 100% in the dried state. The resulting wet or dried three-dimensional architectures provide hydrogel foams with a wide range of useful properties, including very low densities, excellent absorption properties, a large surface-to-volume ratio or tuneable mechanical properties. At the same time, the hydrogel may provide biodegradability, bioabsorption, antifungal or antibacterial activity, or controlled drug delivery. The combination of these properties are increasingly exploited for a wide range of applications, including the biomedical, cosmetic or food sector. The successful formulation of a hydrogel foam from an initially liquid foam template raises many challenging scientific and technical questions at the interface of hydrogel and foam research. Goal of this review is to provide an overview of the key notions which need to be mastered and of the state of the art of this rapidly evolving field at the interface between chemistry and physics.

Mineral plastic foams

We describe a route to synthesize a mechanically stable, non-flammable poly(acrylic acid)-calcium salt (the so-called mineral plastic) foam whose structure can be tailored. Main steps of the foam synthesis are: (1) foaming of the PAA-containing solution, (2) gelation of the continuous foam phase, and (3) drying of the hydrogel foam. The main challenge was to formulate an aqueous solution with a large amount of poly(acrylic acid), PAA, and calcium to yield a mechanically stable foam. The resulting PAA-based solid foams with pore sizes of around 220 μm can easily be dissolved, i.e. recycled, in an acidic solution.

Removal of antibiotics from aqueous solution by using porous adsorbent templated from eco-friendly Pickering aqueous foams

The aqueous foam template without any solvent and only using the particles stabilizer has attracted much attention for preparation of the porous adsorbents. Herein, a novel porous adsorbent was fabricated via thermal-initiated polymerization of Pickering aqueous foams, which was stabilized by the natural sepiolite (Sep) and pine pollen, and utilized for the removal of antibiotic from aqueous solution. The stabilizing mechanism of Pickering aqueous foam of that the Sep was modified with the leaching substance from pine pollen and arranged orderly around the bubble to form a dense "shell" structure was revealed. The adsorbents possessed the hierarchical porous structure and excellent adsorption performance for antibiotic of chlorotetracycline hydrochloride (CTC) and tetracycline hydrochloride (TC). The equilibrium adsorption capacities of CTC and TC were achieved with 465.59 and 330.59 mg/g within 60 min at 25°C, respectively. The adsorption process obeyed Langmuir model and pseudo-second-order adsorption kinetic model. This work provided eco-friendly approach for fabricate porous adsorbents for wastewater treatment.

3D Printing of Liquid Crystal Elastomer Foams for Enhanced Energy Dissipation Under Mechanical Insult

Polymer foams are an essential class of lightweight materials used to protect assets against mechanical insults, such as shock and vibration. Two features are important to enhance their energy absorption characteristics: the foam structure and the matrix phase mechanical behavior. This study investigates novel approaches to control both of these features to enhance the energy absorption capability of flexible lattice foams. First, we consider 3D printing via digital light processing (DLP) as a method to control the foam mesostructure across a suite of periodic unit cells. Second, we introduce an additional energy dissipation mechanism in the solid matrix phase material by 3D printing the lattice foams with polydomain liquid crystal elastomer (LCE), which undergo a mechanically induced phase transition under large strains. This phase transition is associated with LC mesogen rotation and alignment and provides a second mechanism for mechanical energy dissipation in addition to the viscoelastic relaxation of the polymer network. We contrast the 3D printed LCE lattices with conventional, thermomechanically near-equivalent elastomer lattice foams to quantify the energy-absorbing enhancement the LCE matrix phase provides. Under cyclic quasi-static uniaxial compression conditions, the LCE lattices show dramatically enhanced energy dissipation in uniaxial compression compared to the non-LCE equivalent foams printed with a commercially available photocurable elastomer resin. The lattice geometry also plays a prominent role in determining the energy dissipation ratio between the LCE and non-LCE foams. We show that when increasing the lattice connectivity, the foam deformation transitions from bending-dominated to stretching-dominated deformations, which generates higher axial strains in the struts and higher energy dissipation in the lattice foam, as stretching allows greater mesogen rotation than bending. The LCE foams demonstrate superior energy absorption during the repeated dynamic loading during drop testing compared with the non-LCE equivalent foams, demonstrating the potential of LCEs to enhance physical protection systems against mechanical impact.

Current challenges in thermodynamic aspects of rubber foam

Natural rubber (NR) foam can be prepared by the Dunlop method using concentrated natural latex with chemical agents. Most previous studies have focused on the thermodynamic parameters of solid rubber in extension. The main objective of this study is to investigate the effect of the NR matrix concentration on the static and dynamic properties of NR foams, especially the new approach of considering the thermodynamic aspects of NR foam in compression. We found that the density and compression strength of NR foams increased with increasing NR matrix concentration. The mechanical properties of NR foam were in agreement with computational modelling. Moreover, thermodynamic aspects showed that the ratio of internal energy force to the compression force, Fu/F, and the entropy, S, increased with increasing matrix concentration. The activation enthalpy, ∆Ha, also increased with increasing matrix concentration in the NR foam, indicating the greater relaxation time of the backbone of the rubber molecules. New scientific concepts of thermodynamic parameters of the crosslinked NR foam in compression mode are proposed and discussed. Our results will improve both the knowledge and the development of rubber foams based on the structure-properties relationship, especially the new scientific concept of the thermodynamical parameters under compression.

Monolithic Three-Dimensional Functionally Graded Hydrogels for Bioinspired Soft Robots Fabrication

Bioinspired soft robotics aims at reproducing the complex hierarchy and architecture of biological tissues within artificial systems to achieve the typical motility and adaptability of living organisms. The development of suitable fabrication approaches to produce monolithic bodies provided with embedded variable morphological and mechanical properties, typically encountered in nature, is still a technological challenge. Here we report on a novel manufacturing approach to produce three-dimensional functionally graded hydrogels (3D-FGHs) provided with a controlled porosity gradient conferring them variable stiffness. 3D-FGHs are fabricated by means of a custom-designed liquid foam templating (LFT) technique, which relies on the inclusion of air bubbles generated by a blowing agent into the monomer-based template solution during ultraviolet-induced photopolymerization. The 3D-FGHs' apparent Young's modulus ranges from 0.37 MPa (bulky hydrogel region) to 0.09 MPa (highest porosity region). A fish-shaped soft swimmer is fabricated to demonstrate the feasibility of the LFT technique to produce bioinspired robots. Mobility tests show a significant improvement in terms of swimming speed when the robot is provided with a graded body. The proposed manufacturing approach constitutes an enabling solution for the development of macroscopic functionally graded hydrogel-based structures usable in biomimetic underwater soft robotics applications.

Considerations Using Additive Manufacture of Emulsion Inks to Produce Respiratory Protective Filters Against Viral Respiratory Tract Infections Such as the COVID-19 Virus

This review paper explores the potential of combining emulsion-based inks with additive manufacturing (AM) to produce filters for respiratory protective equipment (RPE) in the fight against viral and bacterial infections of the respiratory tract. The value of these filters has been highlighted by the current severe acute respiratory syndrome coronavirus-2 crisis where the importance of protective equipment for health care workers cannot be overstated. Three-dimensional (3D) printing of emulsions is an emerging technology built on a well-established field of emulsion templating to produce porous materials such as polymerized high internal phase emulsions (polyHIPEs). PolyHIPE-based porous polymers have tailorable porosity from the submicron to 100 s of µm. Advances in 3D printing technology enables the control of the bulk shape while a micron porosity is controlled independently by the emulsion-based ink. Herein, we present an overview of the current polyHIPE-based filter applications. Then, we discuss the current use of emulsion templating combined with stereolithography and extrusion-based AM technologies. The benefits and limitation of various AM techniques are discussed, as well as considerations for a scalable manufacture of a polyHIPE-based RPE.

Highly stable and thermo-responsive gel foams by synergistically combining glycyrrhizic acid nanofibrils and cellulose nanocrystals

HYPOTHESIS

Natural saponin glycyrrhizic acid (GA) and GA nanofibrils (GNFs) are effective foaming agents for formulation of aqueous food-grade foams. Through the synergistic combination of soft semiflexible GNFs with rigid nanofiller cellulose nanocrystals (CNCs), it should be possible to create advanced composite foams with a more complex structure and diverse properties including high stability and stimuli responsiveness.

EXPERIMENTS

Foams containing mixtures of GNFs and CNCs were prepared, and their formation and stability were investigated. A range of microscopy techniques and small deformation oscillatory shear were adopted to examine the microstructure and viscoelasticity of foams, and a stabilization mechanism for highly stable foams was then established. Further, the temperature-responsive destabilization of foams was evaluated.

FINDINGS

CNCs are homogeneously distributed in the architecture and mechanically reinforce the GNF fibrillar network, leading to a highly viscoelastic composite network in the continuous phase of foams, which is the key factor responsible for their high stability. Such ultra-stable gel foams display tunable thermo-responsive behavior and a rapid on-demand destabilization upon heating by inducing a phase transition of the bulk composite network. Our work opens up new scenarios on the use of a novel combination of all-natural, sustainable nanoscale building blocks to develop aqueous "superfoams" which are highly stable, stimulable and processable.

Programmable Porous Polymers via Direct Bubble Writing with Surfactant-Free Inks

Fabrication of macroporous polymers with functionally graded architecture or chemistry bears transformative potential in acoustic damping, energy storage materials, flexible electronics, and filtration but is hardly reachable with current processes. Here, we introduce thiol-ene chemistries in direct bubble writing, a recent technique for additive manufacturing of foams with locally controlled cell size, density, and macroscopic shape. Surfactant-free and solvent-free graded three-dimensional (3D) foams without drying-induced shrinkage were fabricated by direct bubble writing at an unparalleled ink viscosity of 410 cP (40 times higher than previous formulations). Functionalities including shape memory, high glass transition temperatures (>25 °C), and chemical gradients were demonstrated. These results extend direct bubble writing from aqueous inks to nonaqueous formulations at high liquid flow rates (3 mL min-1). Altogether, direct bubble writing with thiol-ene inks promises rapid one-step fabrication of functional materials with locally controlled gradients in the chemical, mechanical, and architectural domains.

Recent Progress in Processing Functionally Graded Polymer Foams

Polymer foams are an important class of engineering material that are finding diverse applications, including as structural parts in automotive industry, insulation in construction, core materials for sandwich composites, and cushioning in mattresses. The vast majority of these manufactured foams are homogeneous with respect to porosity and structural properties. In contrast, while cellular materials are also ubiquitous in nature, nature mostly fabricates heterogeneous foams, e.g., cellulosic plant stems like bamboo, or a human femur bone. Foams with such engineered porosity distribution (graded density structure) have useful property gradients and are referred to as functionally graded foams. Functionally graded polymer foams are one of the key emerging innovations in polymer foam technology. They allow enhancement in properties such as energy absorption, more efficient use of material, and better design for specific applications, such as helmets and tissue restorative scaffolds. Here, following an overview of key processing parameters for polymer foams, we explore recent developments in processing functionally graded polymer foams and their emerging structures and properties. Processes can be as simple as utilizing different surface materials from which the foam forms, to as complex as using microfluidics. We also highlight principal challenges that need addressing in future research, the key one being development of viable generic processes that allow (complete) control and tailoring of porosity distribution on an application-by-application basis.

Microfluidic Technology for the Production of Well-Ordered Porous Polymer Scaffolds

Advances in tissue engineering (TE) have revealed that porosity architectures, such as pore shape, pore size and pore interconnectivity are the key morphological properties of scaffolds. Well-ordered porous polymer scaffolds, which have uniform pore size, regular geometric shape, high porosity and good pore interconnectivity, facilitate the loading and distribution of active biomolecules, as well as cell adhesion, proliferation and migration. However, these are difficult to prepare by traditional methods and the existing well-ordered porous scaffold preparation methods require expensive experimental equipment or cumbersome preparation steps. Generally, droplet-based microfluidics, which generates and manipulates discrete droplets through immiscible multiphase flows inside microchannels, has emerged as a versatile tool for generation of well-ordered porous materials. This short review details this novel method and the latest developments in well-ordered porous scaffold preparation via microfluidic technology. The pore structure and properties of microfluidic scaffolds are discussed in depth, laying the foundation for further research and application in TE. Furthermore, we outline the bottlenecks and future developments in this particular field, and a brief outlook on the future development of microfluidic technique for scaffold fabrication is presented.

Micrometric Monodisperse Solid Foams as Complete Photonic Bandgap Materials

Solid foams with micrometric pores are used in different fields (filtering, 3D cell culture, etc.), but today, controlling their foam geometry at the pore level, their internal structure, and the monodispersity, along with their mechanical properties, is still a challenge. Existing attempts to create such foams suffer either from slow speed or size limitations (above 80 μm). In this work, by using a temperature-regulated microfluidic process, 3D solid foams with highly monodisperse open pores (PDI lower than 5%), with sizes ranging from 5 to 400 μm and stiffnesses spanning 2 orders of magnitude, are created for the first time. These features open the way for exciting applications, in cell culture, filtering, optics, etc. Here, the focus is set on photonics. Numerically, these foams are shown to open a 3D complete photonic bandgap, with a critical index of 2.80, thus compatible with the use of rutile TiO₂. In the field of photonics, such structures represent the first physically realizable self-assembled FCC (face-centered cubic) structure that possesses this functionality.

Polyfoam: Foam-Templated Microcellular Polymers

High internal phase emulsion (HIPE) templating has been developed as a robust method for the synthesis of porous polymers with designed porosity and void size. However, it has low starting material efficiency, requiring the removal of over 74% of the starting material to form interconnected porous structures. Foam templating methods attempt to resolve this issue by replacing the internal liquid phase with a gas phase. The current challenge for foam templating is to reach small void sizes (<100 μm), especially when using free-radical polymerization. We use a rapid gas dispersion method to form foam-templated hydrogels, which is an energy-effective method in comparison to the typical HIPE templating approach. We report hydrogels with an average void diameter of 63 μm at 70% porosity. The morphology and properties of foam-templated hydrogels are evaluated to show comparability to the HIPE-templated hydrogels of the same material.

The Overview of Porous, Bioactive Scaffolds as Instructive Biomaterials for Tissue Regeneration and Their Clinical Translation

Porous scaffolds have been employed for decades in the biomedical field where researchers have been seeking to produce an environment which could approach one of the extracellular matrixes supporting cells in natural tissues. Such three-dimensional systems offer many degrees of freedom to modulate cell activity, ranging from the chemistry of the structure and the architectural properties such as the porosity, the pore, and interconnection size. All these features can be exploited synergistically to tailor the cell-material interactions, and further, the tissue growth within the voids of the scaffold. Herein, an overview of the materials employed to generate porous scaffolds as well as the various techniques that are used to process them is supplied. Furthermore, scaffold parameters which modulate cell behavior are identified under distinct aspects: the architecture of inert scaffolds (i.e., pore and interconnection size, porosity, mechanical properties, etc.) alone on cell functions followed by comparison with bioactive scaffolds to grasp the most relevant features driving tissue regeneration. Finally, in vivo outcomes are highlighted comparing the accordance between in vitro and in vivo results in order to tackle the future translational challenges in tissue repair and regeneration.

Highly wet aqueous foams stabilized by an amphiphilic bio-based hydrogelator derived from dehydroabietic acid

Exploration of novel molecular aggregates that stabilize foam systems is helpful to optimize foam properties. Herein, solutions of a rosin-based low-molecular-weight hydrogelator, abbreviated as R-6-AO, were used to generate foams above the critical gelation temperature (Tgel). The foams with R-6-AO concentrations above the critical gelation concentration were very stable below Tgel. The high stability of the foams under such conditions was attributed to the self-assembly of nanoscale fibers of R-6-AO in the liquid films of the foams, leading to extremely slow drainage of water. The foams showed strong water retention and were classified as very wet foams. For example, the foams generated from 10 mM (0.44 wt%) R-6-AO solution subjected to a fast cooling process contained about 45 vol% trapped water after 2000 min. In comparison, the water volume fraction of a 10 mM sodium dodecyl sulfate (SDS) foam decreased from 20 vol% to 1 vol% within 18 min. Because the growth, elongation, and cross-linking of the assembled nanofibers in the liquid films were affected by the cooling process, the stability of these foams also depended on the initial preparation temperature. The present system reveals the importance of microstructures in regulating foam behavior and serves as a new type of condition-sensitive intelligent foam.

Microfluidics Mediated Production of Foams for Biomedical Applications

Within the last decade, there has been increasing interest in liquid and solid foams for several industrial uses. In the biomedical field, liquid foams can be used as delivery systems for dermatological treatments, for example, whereas solid foams are frequently used as scaffolds for tissue engineering and drug screening. Most of the foam functionalities are largely correlated to their mechanical properties and their structure, especially bubble/pore size, shape, and interconnectivity. However, the majority of conventional foaming fabrication techniques lack pore size control which can induce important inhomogeneities in the foams and subsequently decrease their performance. In this perspective, new advanced technologies have been introduced, such as microfluidics, which offers a highly controlled production, allowing for design customization of both liquid foams and solid foams obtained through liquid-templating. This short review explores both the fabrication and the characterization of foams, with a focus on solid polymer foams, and sheds the light on how microfluidics can overcome some existing limitations, playing a crucial role in their production for biomedical applications, especially as scaffolds in tissue engineering.

Formulation and polymerization of foamed 1,4-BDDMA-in-water emulsions

Emulsion and foam templating allow the synthesis of tailor-made polymer foams. A complementary templating route is foamed emulsion templating. The concept is based on the generation of a monomer-in-water emulsion which is subsequently foamed. After polymerization of the foamed emulsion, one obtains open-cell polymer foams with porous pore walls. In the paper at hand, we generated foamed emulsions and synthesized polymer foams which are based on the monomer 1,4-butanediol dimethacrylate (1,4-BDDMA). The main challenge was to find the optimal composition of the emulsion by varying the components systematically. We will discuss that the composition of the monomer-in-water emulsion is key for the stability of the foamed emulsion and thus for the structure of the resulting polymer foam. The final composition of the continuous phase was found to be 65 vol% 1,4-BDDMA, 30 vol% water and 5 vol% glycerol. We foamed and polymerized this emulsion to check the foamed emulsion's suitability as a template for solid polymer foams. We generated a foamed emulsion with a mean bubble diameter of 151 μm ± 90 μm and obtained a highly porous poly(1,4-BDDMA) foam with a pore mean diameter of 366 μm ± 91 μm. Furthermore, the polymer foam has a “sub-porosity” within the pore walls.

Emulsion and foam templating allow the synthesis of tailor-made polymer foams.

Architected Polymer Foams via Direct Bubble Writing

Polymer foams are cellular solids composed of solid and gas phases, whose mechanical, thermal, and acoustic properties are determined by the composition, volume fraction, and connectivity of both phases. A new high-throughput additive manufacturing method, referred to as direct bubble writing, for creating polymer foams with locally programmed bubble size, volume fraction, and connectivity is reported. Direct bubble writing relies on rapid generation and patterning of liquid shell-gas core droplets produced using a core-shell nozzle. The printed polymer foams are able to retain their overall shape, since the outer shell of these bubble droplets consist of a low-viscosity monomer that is rapidly polymerized during the printing process. The transition between open- and closed-cell foams is independently controlled by the gas used, while the foam can be tailored on-the-fly by adjusting the gas pressure used to produce the bubble droplets. As exemplars, homogeneous and graded polymer foams in several motifs, including 3D lattices, shells, and out-of-plane pillars are fabricated. Conductive composite foams with controlled stiffness for use as soft pressure sensors are also produced.