In an aspect, provided herein are low density materials, including shell-based materials, with three-dimensional architectures formed, in part, via self-assembly processes. Shell-based materials of some embodiments exhibit a combination of ultralow density (e.g., ?100 mg cm.sup.?3 and optionally ?10 100 mg cm.sup.?3) and non-periodic architectures characterized by low defect densities and geometries avoiding stress concentrations. Low density shell based materials of some embodiments have architectures characterized by small curvatures and lack of straight edges providing enhance mechanical response. In some embodiments, for example, the present low density materials, including shell-based materials, providing a combination target mechanical properties including high stiffness-to-density ratios, mechanical resilience and tolerance for deformation.

In an aspect, provided herein are low density materials, including shell-based materials, with three-dimensional architectures formed, in part, via self-assembly processes. Shell-based materials of some embodiments exhibit a combination of ultralow density (e.g., ?100 mg cm.sup.?3 and optionally ?10 100 mg cm.sup.?3) and non-periodic architectures characterized by low defect densities and geometries avoiding stress concentrations. Low density shell based materials of some embodiments have architectures characterized by small curvatures and lack of straight edges providing enhance mechanical response. In some embodiments, for example, the present low density materials, including shell-based materials, providing a combination target mechanical properties including high stiffness-to-density ratios, mechanical resilience and tolerance for deformation.

An infiltratable material forms a net shape containing a porous network that can be infiltrated with a supplemental material, commonly referred to as an infiltrant, e.g., by heating the infiltrant so that it melts and wicks into the porous network of the net shape. By using additive fabrication technologies to spatially dispose an infiltrant about an infiltratable structure, a composite structure can be created that advantageously controls the amount of infiltrant applied to the infiltratable structure and the spatial distribution of the infiltrant about and/or within the infiltratable structure prior to infiltration.

The invention relates to a method for economically producing a composite powder made of carbon and electrochemical active material. According to the invention, a melt made of a meltable carbon precursor substance having nanoparticles made of an active material distributed in the melt is provided, and said melt is divided into the composite powder, in which nanoparticles made of the active material are embedded in a matrix made of the carbon precursor substance. A porous composite material produced using the composite powder is used to produce an electrode for a secondary battery, in particular for use as an anode material. The production of the composite material comprises the following steps: providing template particles made of inorganic template material, producing a powder mixture of the composite powder and the template particles, heating the powder mixture and softening the composite powder in such a way that the composite powder penetrates the pores and is carbonated, and removing the template material to form the porous electrochemical composite material.

The invention relates to a method for economically producing a composite powder made of carbon and electrochemical active material. According to the invention, a melt made of a meltable carbon precursor substance having nanoparticles made of an active material distributed in the melt is provided, and said melt is divided into the composite powder, in which nanoparticles made of the active material are embedded in a matrix made of the carbon precursor substance. A porous composite material produced using the composite powder is used to produce an electrode for a secondary battery, in particular for use as an anode material. The production of the composite material comprises the following steps: providing template particles made of inorganic template material, producing a powder mixture of the composite powder and the template particles, heating the powder mixture and softening the composite powder in such a way that the composite powder penetrates the pores and is carbonated, and removing the template material to form the porous electrochemical composite material.

Disclosed are hierarchically porous carbon materials with a plurality of discreet nanoparticles dispersed on their carbon phase. The materials possess a continuous network of pores that spans the porous material, permitting the flow of fluids into and through the material. The porous materials can be used as heterogeneous catalysts.

Disclosed are hierarchically porous carbon materials with a plurality of discreet nanoparticles dispersed on their carbon phase. The materials possess a continuous network of pores that spans the porous material, permitting the flow of fluids into and through the material. The porous materials can be used as heterogeneous catalysts.

A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.

A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.