权利要求：
1. A method for making an additive manufactured foamed article, the method comprising:
placing a foamable article and carbon dioxide (CO2) in a vessel, wherein the foamable article includes a solid foamable material assembled using an additive manufacturing process, wherein the solid foamable material is a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers;
after the placing, maintaining the vessel at a first pressure and first temperature, wherein the first pressure and first temperature are a pressure and temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining includes holding the article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the foamable article;
following the maintaining and holding, optionally exposing the infused article to a second pressure and second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material;
following the maintaining and holding and the optional exposing, subjecting the foamable article to a third pressure and third temperature at which the carbon dioxide infused in the solid foamable material phase transitions to a gas, thereby expanding the solid foamable material into a foamed material and forming the foamed article.
2. The method of claim 1, wherein the article is formed from a plurality of strata in a layer-wise fashion, wherein the plurality of strata comprises at least a first strata and a second strata, and wherein, in the solid foamable article, each strata of the plurality is affixed to at least a portion of another strata.
3. The method of claim 2, wherein each strata of the plurality of strata individually comprises a plurality of particles, an extruded material, or any combination thereof, optionally wherein the plurality of particles, the extruded material, or both are the solid foamable material.
4. The method of claim 2, wherein, in the additive manufactured foamable article, the first strata forms an outermost surface of the additive manufactured article and the second strata forms an inner layer of the additive manufactured article.
5. The method of claim 2, wherein, in the foamable article, the first strata comprises or consists essentially of the solid foamable material, the solid foamable material of the first strata is a first strata solid foamable material, and in the steps of subjecting and expanding, the first strata solid foamable material either remains as the first strata solid foamable material, or expands into the foamed material wherein the foamed material of the first strata is a first strata foamed material.
6. The method of claim 2, wherein, in the foamable article, the second strata comprises or consists essentially of the solid foamable material, the solid foamable material of the second strata is a second strata solid foamable material, and in the steps of subjecting and expanding, the second strata solid foamable material either remains as the second solid strata foamable material, or expands into the foamed material wherein the foamed material of the second strata is a second strata foamed material.
7. The method of claim 2, wherein
the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata, or
wherein the duration of time is sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the second strata, or
wherein the duration of time is sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata and into at least a portion of the second strata;
optionally wherein the duration of time is sufficient for the at least a portion of the liquid carbon dioxide to infuse into substantially all of the first strata, or substantially all of the second strata, or into substantially all of the first strata and the second strata.
8. The method of claim 1, wherein manufacturing the foamable article using an additive manufacturing method comprises extruding at least one first filament or pellet comprising the solid foamable material to form the foamable article.
9. The method of claim 8, wherein the extruding comprises depositing the solid foamable material on a substrate.
10. The method of claim 8, wherein the manufacturing the foamable article further comprises extruding a second filament or pellet, wherein the second filament or pellet comprises a second extruded material.
11. The method of claim 1, wherein the liquid carbon dioxide is soluble in the solid foamable material at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent.
12. The method of claim 10, wherein following the expanding and foaming, the second extruded material remains substantially unfoamed.
13. The method of claim 1, wherein the one or more first thermoplastic elastomers comprise one or more thermoplastic elastomeric polyolefin homopolymers or copolymers, one or more thermoplastic elastomeric polyamide homopolymers or copolymers, one or more thermoplastic elastomeric polyester homopolymers or copolymers, one or more thermoplastic elastomeric polyurethane homopolymers or copolymers, one or more thermoplastic elastomeric styrenic homopolymers or copolymers, or any combination thereof.
14. The method of claim 13, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more thermoplastic polyurethane elastomeric homopolymers or copolymers.
15. The method of claim 14, wherein the one or more first thermoplastic elastomers comprise or consist essentially of thermoplastic polyester-polyurethane elastomers, polyether-polyurethane elastomers, polycarbonate-polyurethane elastomers, or combinations thereof.
16. The method of claim 1, wherein the article comprises an additional material, and wherein during the expanding step, the additional material remains substantially unfoamed.
17. The method of claim 1, wherein the step of subjecting and expanding comprises expanding the foamable material into the foamed material until the foamed material has a density of from about 0.01 gram per cubic centimeter to about 3.0 grams per cubic centimeter.
18. The method of claim 1, wherein the solid foamable material has a Shore A hardness of from about 35 A to about 95 A.
19. The method of claim 1, wherein the additive manufactured foamed article is a component of an article of apparel, footwear, or sporting equipment.
20. An additive manufactured foamed article made according to the method of claim 1.
具体实施方式：
[0016]In one aspect, disclosed herein is a method for making an additive manufactured foamed article, the method comprising placing a foamable article and carbon dioxide (CO2) in a vessel, wherein the foamable article includes a solid foamable material assembled using an additive manufacturing process, wherein the solid foamable material is a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers; after the placing, maintaining the vessel at a first pressure and first temperature, wherein the first pressure and first temperature are a pressure and temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining includes holding the article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the foamable article; following the maintaining and holding, optionally exposing the infused article to a second pressure and second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material; following the maintaining and holding and the optional exposing, subjecting the foamable article to a third pressure and third temperature at which the carbon dioxide infused in the solid foamable material phase transitions to a gas, thereby expanding the solid foamable material into a foamed material and forming the foamed article.
[0017]In another aspect, the method further comprises following the subjecting and expanding, bringing the additive manufactured foamed article to a fourth temperature and fourth pressure, and holding the foamed article at or below the fourth temperature, the fourth pressure, or both, for a duration of time. In still another aspect, the method further comprises following the subjecting and expanding or following the optional bringing, stabilizing the additive manufactured foamed article at a fifth pressure and fifth temperature at which the carbon dioxide diffuses out of the foamed material of the foamed article while maintaining the foamed material in a foam structure, forming a stabilized additive manufactured foamed article.
[0018]In one aspect, manufacturing the foamable article using an additive manufacturing method comprises arranging a plurality of foamable particles, wherein the arranged plurality of foamable particles comprises a solid foamable material, optionally wherein the plurality of particles comprises a blend according to any one of claims 138-151, and optionally wherein the arranged plurality of foamable particles has a number average particle size of about 0.001 millimeters to about 10 millimeters in a longest dimension, or of about 0.04 millimeters to about 10 millimeters in a longest dimension, or of about 1 millimeters to about 5 millimeters in a longest dimension.
[0019]In another aspect, manufacturing the foamable article using an additive manufacturing method comprises extruding at least one first filament or pellet comprising the foamable material to form the foamable article.
[0020]In another aspect, the foamable article can be configured as a series of two or more strata including a first strata comprising a first strata material and a second strata comprising a second strata material, wherein the first strata material or the second strata material or both the first strata material and the second strata material are a solid foamable material; optionally wherein the first strata material and the second strata material are individually a blend, optionally wherein the first strata or the second strata forms an outermost surface of the article, or wherein both the first strata and the second strata individually or jointly form the outermost surface of the foamable article.
[0021]The following list of exemplary aspects supports and is supported by the disclosure provided herein.
[0022]In accordance with Aspect 1, the present disclosure is directed to a method for making an additive manufactured foamed article, the method comprising:
[0023]placing a foamable article and carbon dioxide (CO2) in a vessel, wherein the foamable article includes a solid foamable material assembled using an additive manufacturing process, wherein the solid foamable material is a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers;
after the placing, maintaining the vessel at a first pressure and first temperature, wherein the first pressure and first temperature are a pressure and temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining includes holding the article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the foamable article;
[0024]following the maintaining and holding, optionally exposing the infused article to a second pressure and second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material;
[0025]following the maintaining and holding and the optional exposing, subjecting the foamable article to a third pressure and third temperature at which the carbon dioxide infused in the solid foamable material phase transitions to a gas, thereby expanding the solid foamable material into a foamed material and forming the foamed article.
[0026]In accordance with Aspect 2, the present disclosure is directed to the method of aspect 1, further comprising following the subjecting and expanding, bringing the additive manufactured foamed article to a fourth temperature and fourth pressure, and holding the foamed article at or below the fourth temperature, the fourth pressure, or both, for a duration of time.
[0027]In accordance with Aspect 3, the present disclosure is directed to the method of aspect 1 or 2, further comprising following the subjecting and expanding or following the optional bringing, stabilizing the additive manufactured foamed article at a fifth pressure and fifth temperature at which the carbon dioxide diffuses out of the foamed material of the foamed article while maintaining the foamed material in a foam structure, forming a stabilized additive manufactured foamed article.
[0028]In accordance with Aspect 4, the present disclosure is directed to the method of aspect 3, wherein the stabilizing comprises holding the additive manufactured foamed article at the fifth pressure and fifth temperature for a duration of time sufficient to remove substantially all of the carbon dioxide from the foamed material.
[0029]In accordance with Aspect 5, the present disclosure is directed to the method of any one of the preceding aspects, wherein, at the first pressure and temperature, the liquid carbon dioxide is soluble in the solid foamable material at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent.
[0030]In accordance with Aspect 6, the present disclosure is directed to the method of any one of the preceding aspects, wherein the foamed material of the additive manufactured foamed article is substantially opaque.
[0031]In accordance with Aspect 7, the present disclosure is directed to the method of any one of the preceding aspects, wherein the foamed material has a split-tear value of from about 2.5 kilograms per centimeter to about 3.0 kilograms per centimeter.
[0032]In accordance with Aspect 8, the present disclosure is directed to the method of any one of the preceding aspects, wherein the foamed material has an Asker C hardness of from about 10 to about 50.
[0033]In accordance with Aspect 9, the present disclosure is directed to the method of any one of the preceding aspects, wherein the foamable article is an additive manufactured article.
[0034]In accordance with Aspect 10, the present disclosure is directed to the method of any one of the preceding aspects, further comprising manufacturing the foamable article using an additive manufacturing method.
[0035]In accordance with Aspect 11, the present disclosure is directed to the method of aspect 10, wherein manufacturing the foamable article using an additive manufacturing method comprises arranging a plurality of foamable particles, wherein the arranged plurality of foamable particles comprises a solid foamable material, optionally wherein the plurality of particles comprises a blend according to any one of aspects 138-151, and optionally wherein the arranged plurality of foamable particles has a number average particle size of about 0.001 millimeters to about 10 millimeters in a longest dimension, or of about 0.04 millimeters to about 10 millimeters in a longest dimension, or of about 1 millimeters to about 5 millimeters in a longest dimension.
[0036]In accordance with Aspect 12, the present disclosure is directed to the method of aspect 11, wherein the particles are uniform in size, shape, or both size and shape.
[0037]In accordance with Aspect 13, the present disclosure is directed to the method of aspect 11, wherein the particles are heterogeneous in size and shape.
[0038]In accordance with Aspect 14, the present disclosure is directed to the method of any one of aspects 11-13, further comprising directly sintering the particles to each other to form the foamable article.
[0039]In accordance with Aspect 15, the present disclosure is directed to the method of aspect 14, wherein directly sintering the particles comprises increasing a temperature of a portion of the particles with a directed energy beam so as to at least partially soften or melt defining surfaces of only a portion of the arranged plurality of foamable particles, but not of all of the arranged plurality of foamable particles.
[0040]In accordance with Aspect 16, the present disclosure is directed to the method of aspect 15, wherein the directed energy beam comprises a visible or infrared light beam, optionally wherein the light beam is a laser beam, optionally wherein the laser beam is emitted by a gas dynamic laser, a diode laser, or a lead salt laser.
[0041]In accordance with Aspect 17, the present disclosure is directed to the method of aspect 15 or 16, wherein the laser beam has a wavelength within the infrared spectrum.
[0042]In accordance with Aspect 18, the present disclosure is directed to the method of aspect any one of aspects 10-17, wherein manufacturing the foamable article using an additive manufacturing method further comprises depositing a binding material in a binding material target area, wherein the binding material target area comprises at least a portion of the arranged plurality of foamable particles, and wherein the depositing coats at least a portion of defining surfaces of the arranged plurality of foamable particles with the binding material; and affixing at least a portion of the arranged plurality of foamable particles to each other within the target area, optionally wherein the affixing comprises curing.
[0043]In accordance with Aspect 19, the present disclosure is directed to the method according to aspect 18, wherein the curing comprises solidifying the deposited binding material and binding the deposited binding material to the coated at least a portion of the defining surfaces of the arranged plurality of foamable particles.
[0044]In accordance with Aspect 20, the present disclosure is directed to the method according to aspect 18 or 19, wherein the curing comprises: applying energy to the deposited binding material and the arranged plurality of foamable particles in an amount and for a duration sufficient to soften the solid foamable material of the coated at least a portion of the defining surfaces of the arranged plurality of foamable particles into softened foamable material; and decreasing a temperature of the region of the arranged plurality of foamable particles to a temperature at or below which the softened foamable material re-solidifies into the solid foamable material; thereby affixing at least a portion of the coated at least a portion of the defining surfaces of the arranged plurality of foamable particles in the binding material target area.
[0045]In accordance with Aspect 21, the present disclosure is directed to the method according to aspect 20, wherein the applying energy comprises applying energy to substantially all of the arranged plurality of foamable particles.
[0046]In accordance with Aspect 22, the present disclosure is directed to the method according to aspect 20 or 21, wherein the applying energy comprises applying energy to at least a portion of the binding material target area using a directed energy beam, optionally wherein the directed energy beam is a laser beam.
[0047]In accordance with Aspect 23, the present disclosure is directed to the method according to any one of aspects 20-22, wherein the applying energy comprises applying energy within the infrared spectrum, optionally the far infrared spectrum, the near infrared spectrum, or the mid infrared spectrum.
[0048]In accordance with Aspect 24, the present disclosure is directed to the method according to any one of aspects 20-22, wherein the applying energy comprises applying a thermal energy source, optionally wherein the thermal energy source is an infrared energy source or a microwave energy source.
[0049]In accordance with Aspect 25, the present disclosure is directed to the method according to any one of aspects 20-24, wherein the applying energy comprises applying energy to substantially all of the arranged plurality of foamable particles.
[0050]In accordance with Aspect 26, the present disclosure is directed to the method according to any one of aspects 11-25, wherein the arranging a plurality of foamable particles comprises forming one or more strata comprising the plurality of foamable particles.
[0051]In accordance with Aspect 27, the present disclosure is directed to the method according to aspect 26, wherein the article is formed from a single strata comprising the plurality of foamable particles.
[0052]In accordance with Aspect 28, the present disclosure is directed to the method according to aspect 27, wherein an iteration of the arranging comprises forming a strata comprising the plurality of foamable particles.
[0053]In accordance with Aspect 29, the present disclosure is directed to the method according to aspect 28, wherein the article is formed from a plurality of strata in a layer-wise fashion, wherein each strata comprises a plurality of foamable particles, and wherein, in the foamable article, each strata is affixed to at least a portion of another strata.
[0054]In accordance with Aspect 30, the present disclosure is directed to the method of any one of the preceding aspects, wherein the foamable article is configured as a series of two or more strata including a first strata comprising a first strata material and a second strata comprising a second strata material, wherein the first strata material or the second strata material or both the first strata material and the second strata material are a solid foamable material; optionally wherein the first strata material and the second strata material are individually a blend according to any one of aspects 139-152, optionally wherein the first strata or the second strata forms an outermost surface of the article, or wherein both the first strata and the second strata individually or jointly form the outermost surface of the foamable article.
[0055]In accordance with Aspect 31, the present disclosure is directed to the method of aspect 30, wherein the two or more strata individually comprise a plurality of particles, an extruded material, or any combination thereof, optionally wherein the plurality of particles, the extruded material, or both are a solid foamable material.
[0056]In accordance with Aspect 32, the present disclosure is directed to the method of aspect 30 or 31, wherein the first strata comprises a first plurality of particles and the second strata comprises a second plurality of particles.
[0057]In accordance with Aspect 33, the present disclosure is directed to the method of aspect 30 or 31, wherein the first strata comprises a first extruded material and the second strata comprises a second plurality of particles.
[0058]In accordance with Aspect 34, the present disclosure is directed to the method of aspect 30 or 31, wherein the first strata comprises a first plurality of particles and the second strata comprises a second extruded material.
[0059]In accordance with Aspect 35, the present disclosure is directed to the method of aspect 30 or 31, wherein the first strata comprises a first extruded material and the second strata comprises a second extruded material.
[0060]In accordance with Aspect 36, the present disclosure is directed to the method of any one of aspects 30-35, wherein, in the additive manufactured foamable article, the first strata forms the outermost surface of the additive manufactured article and the second strata forms an inner layer of the additive manufactured article.
[0061]In accordance with Aspect 37, the present disclosure is directed to the method of any one of aspects 30-36, wherein, in the foamable article, the first strata comprises or consists essentially of the solid foamable material, the solid foamable material of the first strata is a first strata solid foamable material, and in the steps of subjecting and expanding, the first strata solid foamable material either remains as the first strata solid foamable material, or expands into the foamed material wherein the foamed material of the first strata is a first strata foamed material.
[0062]In accordance with Aspect 38, the present disclosure is directed to the method of any one of 30-37, wherein, in the foamable article, the second strata comprises or consists essentially of the solid foamable material, the solid foamable material of the second strata is a second strata solid foamable material, and in the steps of subjecting and expanding, the second strata solid foamable material either remains as the second solid strata foamable material, or expands into the foamed material wherein the foamed material of the second strata is a second strata foamed material.
[0063]In accordance with Aspect 39, the present disclosure is directed to the method of any one of 30-38, wherein the first strata solid foamable material, or the second strata solid foamable material, or both, is individually a solid foamable material according to any of aspects 1-9 or 124-152.
[0064]In accordance with Aspect 40, the present disclosure is directed to the method of any one of 30-38, wherein the first strata foamed material, or the second strata foamed material, or both, individually are a foamed material according to any of aspects 1-9 or 124-152.
[0065]In accordance with Aspect 41, the present disclosure is directed to the method of any one of aspects 30-40, wherein the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata, or wherein the duration of time is sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the second strata, or wherein the duration of time is sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata and into at least a portion of the second strata; optionally wherein the duration of time is sufficient for the at least a portion of the liquid carbon dioxide to infuse into substantially all of the first strata, or substantially all of the second strata, or into substantially all of the first strata and the second strata.
[0066]In accordance with Aspect 42, the present disclosure is directed to the method of aspect 41, wherein
[0067]the first strata comprises or consists essentially of the first strata solid foamable material,
[0068]the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata solid foamable material, and
[0069]the steps of subjecting and expanding include expanding the at least a portion of the first strata solid foamable material into the foamed material, wherein the foamed material of the first strata comprises a first strata foamed material,
[0070]optionally wherein the expanding includes expanding substantially all of the solid foamable material of the first strata into the first strata foamed material.
[0071]In accordance with Aspect 43, the present disclosure is directed to the method of aspect 41, wherein
[0072]the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for the at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata, wherein the duration of time is not sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the second strata;
[0073]and the steps of subjecting and expanding include expanding the at least a portion of the first strata solid foamable material into the first strata foamed material without expanding the second strata material;
[0074]optionally wherein, following the steps of maintaining and holding, the second strata is substantially free of infused carbon dioxide, and
[0075]optionally wherein the second strata comprises or consists essentially of a barrier material.
[0076]In accordance with Aspect 44, the present disclosure is directed to the method of aspect 41, wherein
[0077]the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for the at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata and into the at least a portion of the second strata, and the method further comprises the step of exposing the infused article to the second pressure and second temperature for a duration of time such that the at least a portion of carbon dioxide infused into the at least a portion of the second strata diffuses out of the at least a portion of the second strata, while at least a portion of the infused carbon dioxide infused in the first strata remains infused in the at least a portion of the first strata following the exposing;
[0078]and the steps of subjecting and expanding include expanding the at least a portion of the solid foamable material of the first strata into the first strata foamed material without expanding the second strata material of the second strata, thereby forming a foamed first strata while maintaining the second strata in a solid unfoamed state;
[0079]optionally wherein, following the step of exposing, the second strata is substantially free of infused carbon dioxide.
[0080]In accordance with Aspect 45, the present disclosure is directed to the method of any one of aspects 30-40, wherein the step of placing comprises placing the foamable article in the liquid carbon dioxide in the vessel such that the article is not fully immersed in the liquid carbon dioxide.
[0081]In accordance with Aspect 46, the present disclosure is directed to the method of aspect 45, wherein the first strata is immersed in the liquid carbon dioxide and the second strata is not immersed in the liquid carbon dioxide, and wherein, following the step of exposing, the second strata is substantially free of infused carbon dioxide.
[0082]In accordance with Aspect 47, the present disclosure is directed to the method of any one of aspects 30-40, wherein
[0083]the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the second strata, or
[0084]wherein the duration of time is sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata and into at least a portion of the second strata;
[0085]optionally wherein the duration of time is sufficient for the at least a portion of the liquid carbon dioxide to infuse into substantially all of the second strata, or substantially all of the second strata, or into substantially all of the first strata and the second strata.
[0086]In accordance with Aspect 48, the present disclosure is directed to the method of aspect 47, wherein
[0087]the second strata comprises or consists essentially of the solid foamable material,
[0088]the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the second strata solid foamable material, and
[0089]the steps of subjecting and expanding include expanding the at least a portion of the second strata solid foamable material into the foamed material, wherein the foamed material of the second strata comprises a second strata foamed material,
[0090]optionally wherein the expanding includes expanding substantially all of the second strata solid foamable material into the strata regional foamed material.
[0091]In accordance with Aspect 49, the present disclosure is directed to the method of aspect 47, wherein
[0092]the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for the at least a portion of the liquid carbon dioxide to infuse into at least a portion of the second strata, wherein the duration of time is not sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata;
[0093]and the steps of subjecting and expanding include expanding the at least a portion of the second strata solid foamable material into the second strata foamed material without expanding the first strata material, thereby forming a foamed second strata while maintaining the first strata in a solid unfoamed state;
[0094]optionally wherein, following the steps of maintaining and holding, the first strata is substantially free of infused carbon dioxide.
[0095]In accordance with Aspect 50, the present disclosure is directed to the method of aspect 47, wherein
[0096]the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for the at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata and into the at least a portion of the second strata, and the method further comprises the step of exposing the infused article to the second pressure and second temperature for a duration of time such that the at least a portion of carbon dioxide infused into the at least a portion of the first strata diffuses out of the at least a portion of the first strata, while at least a portion of the infused carbon dioxide infused in the second strata remains infused in the at least a portion of the second strata following the exposing;
[0097]and the steps of subjecting and expanding include expanding the at least a portion of the second strata solid foamable material into the second strata foamed material without expanding the first strata material;
[0098]optionally wherein, following the step of exposing, the first strata is substantially free of infused carbon dioxide.
[0099]In accordance with Aspect 51, the present disclosure is directed to the method of any one of aspects 30-40, wherein
[0100]the first strata comprises or consists of the solid foamable material, the solid foamable material of the first strata being a first strata solid foamable material;
[0101]the second strata comprises or consists essentially of the solid foamable material, the solid foamable material of the second strata being a second solid strata foamable material;
[0102]the step of maintaining and holding includes holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into at least a portion of the first strata and into at least a portion of the second strata; and
[0103]the steps of subjecting and expanding expands at least a portion of the first strata solid foamable material into a first strata foamed material, and expands at least a portion of the second regional strata foamable material into a second strata foamed material,
[0104]optionally wherein the expanding includes expanding substantially all of the first strata solid foamable material or substantially all of the second strata solid foamable material, or expanding substantially all of the first strata solid foamable material and substantially all of the second strata solid foamable material.
[0105]In accordance with Aspect 52, the present disclosure is directed to the method of aspect 51, wherein, in the additive manufactured foamed article, the first strata foamed material and the second strata foamed material are in contact with each other.
[0106]In accordance with Aspect 53, the present disclosure is directed to the method of aspect 51, wherein, in the additive manufactured foamed article, the first strata foamed material and the second strata foamed material are not in contact with each other.
[0107]In accordance with Aspect 54, the present disclosure is directed to the method of any one of aspects 30-53, wherein the foamable article is configured as a series of three or more strata, further comprising a third strata including a third comprising or consisting essentially of a third strata material,
[0108]optionally wherein the third strata material comprises or consists essentially of a third strata solid foamable material,
[0109]optionally wherein the third strata foamable material is a blend according to any one of aspects 138-151, and
[0110]optionally wherein the third strata is positioned between the first strata and the second strata.
[0111]In accordance with Aspect 55, the present disclosure is directed to the method of aspect 54, wherein the third strata comprises a third plurality of particles.
[0112]In accordance with Aspect 56, the present disclosure is directed to the method of aspect 54, wherein the third strata comprises a third extruded material.
[0113]In accordance with Aspect 57, the present disclosure is directed to the method of aspect 54, wherein the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the first strata, or into the first strata and the second strata, or into the second strata, or into the second strata and the third strata, or into the third strata, or into the third strata and the first strata.
[0114]In accordance with Aspect 58, the present disclosure is directed to the method of any one of aspects 54-57, wherein the steps of maintaining and holding include holding the foamable article and the liquid carbon dioxide in the vessel for a duration of time sufficient for liquid carbon dioxide to infuse into one or two of the three strata but not into the other of the three strata;
[0115]optionally wherein the carbon dioxide infuses into the first strata but not substantially into the second strata, or into the first strata but not substantially into the third strata, or into the second strata but not substantially into the first strata, or into the second strata but not substantially into the third strata, or into the third strata but not substantially into the first strata, or into the third strata but not substantially into the second strata; or
[0116]optionally wherein the carbon dioxide infuses into the first strata and into the second strata but not substantially into the third strata, or into the first strata and the third strata but not substantially into the second strata, or into the second strata and the third strata but not substantially into the first strata.
[0117]In accordance with Aspect 59, the present disclosure is directed to