Freeform Fabrication of Stochastic and Ordered Cellular Structures

Cellular materials provide a unique challenge to SFF technology. Such materials have unique properties of low mass, high strength, and good insulation properties. To produce such cellular structures, SFF systems require a designed microstructure with a feature size significantly lower than the resolution of the process. In this paper, we examine means of producing stochastic foams using the instability of a viscous thread and various methods for production of closed celled foams. These techniques allow for the production of foams without the need for pre-described cell structures. Such foams, when made from elastic materials can act as novel actuating materials.