A method for manufacturing cellular metals with open- and close-type porosities

New approach for manufacturing metallic cellular materials with controlled open pore geometry and cells arrangement is presented. The method is based on the combination of rapid prototyping of a template with powder metallurgy. Modification of the procedure allows for additional introduction of closed-type porosity with pores smaller than those defined by the rapid prototyped template. The accuracy of the method for controlling the size, shape and arrangement of open-type pores is presented on the example of zinc with an inorganic template (CuSO4). The same materials are used to produce a structure with two types of porosities combined in one structure, regular opened and irregular closed. The control of pore geometry allows for optimization of metallic cellular materials for their mechanical, chemical and biological applications.

Research highlights
► Controlled shape, size and cell arrangement of open-type porosity.
► Possibility to combine open- and close-type porosity in one structure.
► Close-type porosity obtained without melting the metal.
► Low cost alternative for direct laser deposition.