A method of making a syntactic-foam part that includes loading a first pre-made component into a mold such that an interstitial space is defined between the first pre-made component and at least one of a second pre-made component within the mold and an inner perimeter of the mold. The first pre-made component includes low-density spheres embedded in a first resin that has been solidified. The method also includes introducing a second resin into the interstitial space. The method further includes solidifying the second resin after the second resin is introduced into the interstitial space.

A method of making a syntactic-foam part includes positioning at least one thermally-conductive media layer within a mold such that at least a portion of the at least one thermally-conductive media layer is spaced apart from an interior surface of the mold. The method also includes loading low-density spheres into the mold so they surround the at least one thermally-conductive media layer. The method further includes introducing a resin into the mold so that the at least one thermally-conductive layer and the low-density spheres are embedded within the resin. The at least one thermally-conductive media layer has a thermal conductivity that is greater than a thermal conductivity of the low-density spheres and the resin. The method additionally includes solidifying the resin after the resin is introduced into the mold. The method also includes transferring heat through the at least one thermally-conductive media layer when the resin is being solidified.

Examples of the present disclosure include an apparatus that includes a syntactic-foam part. The syntactic-foam part includes low-density spheres at least partially embedded in a resin. The syntactic-foam part includes an elongated member partially embedded in the resin and including a first end and a second end. At least the first end is located relative to the syntactic-foam part such that the first end is exposed to an exterior of the syntactic-foam part at an exterior surface of the syntactic-foam part.

A method of making a syntactic-foam part includes loading low-density spheres into a mold. The method also includes introducing a first resin into the mold. The method further includes coating the low-density spheres with the first resin to form a coating, made of the first resin, around an entirety of each one of the low-density spheres. The method additionally includes solidifying the first resin after the first resin is coated on the low-density spheres. The method also includes solidifying the second resin after the second resin fills the mold.

Disclosed herein is a syntactic-foam part and associated methods for making the syntactic-foam part using a mold. The syntactic-foam part includes low-density spheres with at least one inner distribution media layer positioned within the low-density spheres at a predetermined height, that are encapsulated in a resin. The at least one inner distribution media layer facilitates resin flow along an entirety of the at least one distribution media layer before flowing out of the at least one inner distribution media layer, thus resetting a resin level at an infusion interface during an infusion process.

Disclosed herein is a syntactic-foam part and method of making the same. The method includes loading micro-sized low-density spheres into a mold having macro-permitted regions and macro-restricted regions. The method also includes loading macro-sized low-density spheres in the mold so that they are surrounded by micro-sized low-density spheres and each one is spaced apart from any other one of the macro-sized low-density spheres. All of the macro-sized low-density spheres are entirety within the macro-permitted regions of the mold. The method further includes introducing a resin into and filling the mold to embed the micro-sized low-density spheres and macro-sized low-density spheres and solidifying the resin after it fills the mold.

Microspheres refer to micro-particle dispersion systems formed by pharmaceutical molecules dispersed or adsorbed in polymer carriers such as albumin, gelatin and polylactide; and their particle sizes are different from microns to hundreds of microns.