Particle-stabilized liquid foams provide a general route for producing low-density macroporous materials from melt-processable and intractable thermoplastic polymers. In this paper, we demonstrate how these liquid foams can be used to design macroporous polymers with tailored microstructures and properties by adjusting the various processing parameters. By varying the size, concentration, and wettability of the particles in the colloidal suspensions and controlling the frothing, drying, and sintering conditions, macroporous materials with porosities between 33 and 95% and median pore sizes (D50) between 13 and 634 μm were obtained. This foaming process is applicable to a wide range of hydrophobic materials and is demonstrated here on commercially available polymeric powders of poly(tetrafluoroethylene) (PTFE), poly(vinylidene fluoride) (PVDF), poly(ether imide) (PEI), and poly(ether ether ketone) (PEEK).
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