True Foam Photopolymers for Vat Photopolymerisation: Foaming Routes, Network Mobility and Cellular-Structure Qualification
Segurola, Juan
2026-08-27 · Informe · Versión 1.1
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Vat photopolymerisation (VPP) offers high geometric fidelity but normally produces densely crosslinked thermosets whose network mobility can oppose gas-driven expansion. Recent research has addressed this conflict by stabilising air directly in photocurable precursors, incorporating thermally expandable microspheres before printing, or designing dynamic networks that regain mobility during thermal or supercritical-fluid foaming. These strategies create genuinely cellular polymers rather than merely architected porous geometries. The engineering problem is therefore coupled: the formulation must remain optically and rheologically printable, the green or cured network must tolerate cell formation, and the resulting foam must be characterised by density, cell morphology, anisotropy and class-appropriate mechanical tests. This review proposes a route-based taxonomy and a minimum-reporting framework for true VPP foams. Values reported in individual studies are treated as formulation- and process-specific demonstrations, not universal performance limits. A separate implementation section describes the 3Dresyns thermally activated post-print foaming route as manufacturer evidence requiring formulation-specific validation.