A computer-controlled method for forming a composition-controlled product using 3D printing includes disposing two or more liquid reactant compositions in respective two or more reservoirs; and mixing the two or more liquid reactant compositions, which in turn includes controlling by the computer a mass ratio of the mixed two or more liquid reactant compositions. The computer-controlled method further includes scanning, under control of the computer, a mixed liquid reactants nozzle over a substrate; depositing the mixed liquid reactant compositions onto the substrate; and operating, under control of the computer, a light source to polymerize the deposited mixed liquid reactant compositions.

In general, in various embodiments, the present disclosure is directed systems and methods for producing a porous surface from a solid piece of polymer. In particular, the present disclosure is directed to systems that include a track assembly, mold assembly, press assembly, and methods for using the same for producing a porous surface from a solid piece of polymer. In some embodiments, the present systems and methods are directed to processing a polymer at a temperature below a melting point of the polymer to produce a solid piece of polymer with an integrated a porous surface.

Sponge-like porous polypropylene thin film, and a method for preparing a sponge-like porous polypropylene thin film. The method includes dissolving polypropylene in an organic solvent to form a solution under reflux condition; adding a cavity forming agent to the solution and mixing the solution until the cavity forming agent is well-dispersed therein; applying the well-dispersed solution onto the solid substrate through spin coating to form a thin film on the solid substrate; peeling the thin film off the solid substrate; extracting the cavity forming agent from the peeled thin film by washing the peeled thin film in an aqueous or nonaqueous solvent, thereby obtaining a sponge-like porous polypropylene thin film with cavities, macro-voids, and micropores. The sponge-like porous polypropylene thin film is used as an oil sorbent. The sponge-like porous polypropylene thin film has about 400 to about 700 swellable cavities per cm.sup.2.

In general, in various embodiments, the present disclosure is directed systems and methods for producing a porous surface from a solid piece of polymer. In particular, the present disclosure is directed to systems that include a track assembly, mold assembly, press assembly, and methods for using the same for producing a porous surface from a solid piece of polymer. In some embodiments, the present systems and methods are directed to processing a polymer at a temperature below a melting point of the polymer to produce a solid piece of polymer with an integrated a porous surface.

Devices and methods for making a polymer with a porous layer from a solid piece of polymer are disclosed. In various embodiments, the method includes heating a surface of a solid piece of polymer to a processing temperature and holding the processing temperature while displacing a porogen layer through the surface of the polymer to create a matrix layer of the solid polymer body comprising the polymer and the porogen layer. In at least one embodiment, the method also includes removing at least a portion of the layer of porogen from the matrix layer to create a porous layer of the solid piece of polymer.

Freestanding porous polyethylene thin film, and a method for preparing a freestanding porous polyethylene thin film. The method includes dissolving polyethylene in an organic solvent to form a solution under reflux conditions; adding a swellable pocket forming agent to the solution and mixing the solution until the swellable pocket forming agent is well-dispersed therein; applying the well-dispersed solution onto a solid substrate through spin coating to form a thin film on the solid substrate; peeling the thin film off the solid substrate; and extracting the swellable pocket forming agent from the peeled thin film by washing the peeled thin film in water, thereby obtaining a freestanding porous polyethylene thin film with swellable pockets, macro-voids, and micropores. The freestanding porous polyethylene thin film can be used as an oil sorbent. The freestanding porous polyethylene thin film has about 500 to about 800 swellable cavities per cm.sup.2.

A method for making a polymer with a porous layer from a solid piece of polymer is disclosed. In various embodiments, the method includes heating a surface of a solid piece of polymer to a processing temperature and holding the processing temperature while displacing a porogen layer through the surface of the polymer to create a matrix layer of the solid polymer body comprising the polymer and the porogen layer. In at least one embodiment, the method also includes removing at least a portion of the layer of porogen from the matrix layer to create a porous layer of the solid piece of polymer.

A method for making a polymer with a porous layer from a solid piece of polymer is disclosed. In various embodiments, the method includes heating a surface of a solid piece of polymer to a processing temperature and holding the processing temperature while displacing a porogen layer through the surface of the polymer to create a matrix layer of the solid polymer body comprising the polymer and the porogen layer. In at least one embodiment, the method also includes removing at least a portion of the layer of porogen from the matrix layer to create a porous layer of the solid piece of polymer.

In general, in various embodiments, the present disclosure is directed systems and methods for producing a porous surface from a solid piece of polymer. In particular, the present disclosure is directed to systems that include a track assembly, mold assembly, press assembly, and methods for using the same for producing a porous surface from a solid piece of polymer. In some embodiments, the present systems and methods are directed to processing a polymer at a temperature below a melting point of the polymer to produce a solid piece of polymer with an integrated a porous surface.

A method for forming a thermoplastic body having regions with varied material composition and/or porosity. Powder blends comprising a thermoplastic polymer, a sacrificial porogen and an inorganic reinforcement or filler are molded to form complementary parts with closely toleranced mating surfaces. The parts are formed discretely, assembled and compression molded to provide a unitary article that is free from discernible boundaries between the assembled parts. Each part in the assembly has differences in composition and/or porosity, and the assembly has accurate physical features throughout the sections of the formed article, without distortion and nonuniformities caused by variable compaction and densification rates in methods that involve compression molding powder blends in a single step.