A method of making a foamed article, for example a foamed component for an article or footwear, comprises forming a structure of interconnected, unfoamed, thermoplastic polymeric members spaced to define openings between the thermoplastic polymeric members. The structure may be made by printing a thermoplastic polymeric material with a three-dimensional printer. The thermoplastic polymeric members are heated to a first temperature to soften the thermoplastic polymeric members and the softened thermoplastic polymeric members are infused with at least one inert gas at a first pressure greater than atmospheric pressure. The first pressure is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymeric members. After being infused with the inert gas, the pressure is reduced to at least partially foam the thermoplastic polymeric members.

A method for generating a microstructure that includes microcellular bubbles, in a material that includes molecules of a thermoplastic polymer, comprises: determining a size-index for the material that represents an average size of the thermoplastic polymer molecules included in the material, and in response to the determined size-index, setting a parameter of a process to generate a microstructure in the material that includes microcellular bubbles. The process to generate a microstructure in the material includes: 1) infusing into the material, during a first period, a gas that does not react with the material, 2) making the gas-infused material thermodynamically unstable.

A compressible adjunct has a first portion, a second portion, and a middle portion. The middle portion is disposed between the first portion and the second portion. The middle portion comprises a first pillar, a second pillar, and an interconnecting member. The first pillar and the second pillar extend substantially between the first portion and the second portion. The interconnecting member is configured to engage at least the first pillar and the second pillar. When the compressible adjunct is compressed by a force, the first pillar is configured to deflect a first deflection and the second pillar is configured to deflect a second deflection. The first deflection differs from the second deflection.

A staple cartridge assembly comprising an implantable layer is disclosed. The implantable layer comprises a top portion, a bottom portion, and structural walls interwoven between the top portion and the bottom portion.

Pellets, beads, particles, or other pieces of a thermoplastic elastomer having a maximum size in at least one dimension of 10 mm or less (collectively, pellets) are infused with a supercritical fluid in a pressurized container, then rapidly depressurized and heated either by immersion in a heated fluid or with infrared or microwave radiation to foam the pellets The pellets are prepared with at least two different densities. Pellets with different densities, thermoplastic elastomer compositions, or foam response rates are placed in different areas of a mold. The mold is filled with pellets, then the pellets are molded into a part. The part has areas of different density as a result of the placement of pellets of different density.

A method of microcellular foam molding an article includes feeding plastic granules to a hopper; supplying a supercritical fluid (SCF) to the hopper to effuse through the plastic granules; conveying the effused plastic granules to a mixer; and conveying the effused plastic granules in the mixer to a mold of an injection molding machine to perform foam molding on the effused plastic granules to produce a foamed article. In a second embodiment, the injection molding machine is replaced by an extrusion press.

A method for producing porous materials is disclosed. The porous materials can be produced by expansion of polymer gels.

A method of foaming and shaping a thermoplastic sheet comprising a poly(phenylene ether), a polyetherimide, or a combination thereof includes foaming the thermoplastic sheet with supercritical carbon dioxide to form a foamed thermoplastic sheet, and shaping the foamed thermoplastic sheet to form a shaped foamed thermoplastic sheet. The shaping step includes compressing the foamed thermoplastic sheet between a first metal plate and a secondi metal plate, each of which has a grooved surface facing the thermoplastic sheet. The first metal plate and the second metal plate are connected by a flexible, compressible linkage capable. When the flexible, compressible linkage is in its uncompressed state, only the second (lower) metal plate is in contact with the shaped foamed thermoplastic sheet. When the flexible, compressible linkage is in its compressed state, both the first (upper) and second (lower) metal plates are in contact with the shaped foamed thermoplastic sheet.

Foamed articles including a foamed thermoplastic elastomeric material, methods of making the foamed articles, and methods for manufacturing articles of footwear, apparel, and athletic equipment incorporating such foamed articles are provided. In one aspect, a method for making a foamed article comprises placing an article comprising a foamable material and carbon dioxide in a vessel, maintaining the vessel at a first pressure and first temperature at which the carbon dioxide is a liquid and carbon dioxide is soluble in the foamable material, optionally exposing the infused article to a second temperature and second pressure, and subjecting the article to a third pressure and third temperature at which the infused carbon dioxide phase transitions to a gas, thereby expanding the foamable material into a foamed material and forming the foamed article.

A method for the production of cellular plastic particles comprising the steps: providing a plastic material in the form of compact plastic material particles, loading of the compact plastic material particles with at least one blowing agent under the influence of pressure, expanding the plastic material particles loaded with at least one blowing agent to produce cellular plastic particles under the influence of temperature.