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A process for producing a rigid reticulated article involves coating a reticulated substrate which has open, interconnected porosity with a first dispersion comprising a ceramic or metal powder to form a first coating thereon; drying the coated reticulated substrate; contacting the coated reticulate

A process for producing a rigid reticulated article involves coating a reticulated substrate which has open, interconnected porosity with a first dispersion comprising a ceramic or metal powder to form a first coating thereon; drying the coated reticulated substrate; contacting the coated reticulated substrate with one or more additional dispersions in succession to form one or more additional coatings thereon; drying the additional coatings between the steps of contacting; heating the coated reticulated substrate to pyrolyze organic components; and sintering the coated reticulated substrate to form a reticulated article, wherein each dispersion has a viscosity less than that of all preceding dispersions. A rigid reticulated article includes inner, intermediate and outer sintered layers of material in which the inner and outer layers are of different composition and the intermediate layer is a composite of the inner and outer layers.

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1. A process for producing a rigid reticulated article, comprising:(a) providing a first dispersion of a ceramic or metal powder, a binder, and a solvent;(b) providing a reticulated substrate which has open, interconnected porosity;(c) contacting the reticulated substrate with the first dispersion t

1. A process for producing a rigid reticulated article, comprising:(a) providing a first dispersion of a ceramic or metal powder, a binder, and a solvent;(b) providing a reticulated substrate which has open, interconnected porosity;(c) contacting the reticulated substrate with the first dispersion to coat the substrate with the dispersion to form a first coating;(d) drying the coated reticulated substrate;(e) contacting the coated reticulated substrate with one or more additional dispersions of a ceramic or metal powder, a binder, and a solvent, in succession, to form one or more additional coatings wherein each additional dispersion has a viscosity less than the viscosity of all preceding dispersions;(f) drying the one or more additional coatings between the steps of contacting;(g) heating the coated reticulated substrate at a time and temperature sufficient to pyrolyze any organic components; and(h) sintering the coated reticulated substrate to form a ceramic or metal or composite reticulated article.2. A process according to claim 1, wherein after drying the first coating and the one or more additional coatings form an insoluble, flexible film which can be subsequently deformed without substantially cracking off, flaking off or peeling off of the substrate.3. A process according to claim 1, wherein the substrate is compliant.4. A process according to claim 1, wherein the substrate is wettable.5. A process according to claim 1, wherein the pores of the rigid reticulated article are substantially fully open and interconnected.6. A process according to claim 1, wherein up to six additional dispersions are provided to form up to six additional coatings.7. A process according to claim 6, wherein the viscosity of the first dispersion is from 200?2500 cP.8. A process according to claim 1, wherein the reticulated substrate is a compliant polymeric foam.9. A process according to claim 8, wherein the foam has at least 20 pores per inch.10. A process according to claim 8, wherein the foam has at least 100 pores per inch.11. A process according to claim 1, wherein excess dispersion is removed from the reticulated substrate by squeezing and/or compressed air.12. A process according to claim 1, wherein the binder becomes solvent-insoluble and is compliant upon drying.13. A process according to claim 12, wherein the binder is a polyacrylate emulsion which polymerizes upon drying.14. A process according to claim 12, wherein the binder is present in the dispersion in an amount of at least 25% by volume.15. A process for producing a rigid reticulated article, comprising:(a) providing a first dispersion of a ceramic or metal powder, a binder, and a solvent;(b) providing a reticulated substrate which has open, interconnected porosity;(c) contacting the reticulated substrate with the first dispersion to coat the substrate with the dispersion to form a first coating;(d) drying the coated reticulated substrate;(e) contacting the reticulated substrate with one or more additional dispersions of a ceramic or metal powder, a binder, and a solvent to form one or more additional coatings;(f) drying the additional coating between the steps of contacting;(g) heating the coated reticulated substrate at a time and temperature sufficient to pyrolyze any organic components; and(h) sintering the coated reticulated substrate to form a ceramic or metal or composite reticulated article, wherein up to six additional coatings are provided, the viscosity of the first dispersion is from 200?2500 cP, the viscosity of the dispersion of the first additional coating is from 100?1500 cP, the viscosity of the dispersion of the second additional coating is from 50?800 cP, and the viscosity of the dispersion of the third additional coating is 200 cP or less.16. A process for producing a rigid reticulated article, comprising:(a) providing a first dispersion of a ceramic or metal powder, a binder, and a solvent;(b) providing a reticulated substrate which has open, interconnected porosity;(c) contacting the reticulated substrate with the first dispersion to coat the substrate with the dispersion to form a first coating;(d) drying the coated reticulated substrate;(e) contacting the reticulated substrate with one or more additional dispersions in succession to form one or more additional coatings;(f) drying the additional coating between the steps of contacting;(g) heating the coated reticulated substrate at a time and temperature sufficient to pyrolyze any organic components; and(h) sintering the coated reticulated substrate to form a ceramic or metal or composite reticulated article, wherein at least two and up to six additional coatings are provided, the composition of the first coating is different than the composition of the final coating, and one or more intermediate coatings has a composition which is a composite of the first and final coatings to form a gradient coating.17. A process according to claim 16, wherein the first coating comprises zirconia, the final coating comprises hydroxyapatite calcium phosphate ceramic, and an intermediate coating comprises a combination of zirconia and hydroxyapatite calcium phosphate ceramic.18. A process according to claim 16, wherein a successive dispersion has a lower viscosity than a preceding dispersion.19. A process according to claim 18, wherein each dispersion has a lower viscosity than the preceding dispersions.20. A process according to claim 16, wherein a successive dispersion has the same viscosity as a preceding dispersion.21. A process for producing a rigid reticulated article, comprising:(a) providing a first dispersion of a metal or ceramic powder, a binder which becomes solvent-insoluble and polymerizes upon drying, and a solvent, wherein the binder is present in the dispersion in an amount of at least 25% by volume based on the entire volume of the solid components of the dispersion following drying;(b) providing a reticulated substrate which has open, interconnected porosity;(c) contacting the reticulated substrate with the first dispersion to coat the substrate with the dispersion;(d) drying the coated reticulated substrate to polymerize the binder and form an insoluble deformable film on the substrate;(e) optionally contacting the coated reticulated substrate with one or more additional dispersions to form one or more additional coatings wherein the one or more additional coatings are the same or different from each other and the first coating;(f) drying the one or more additional coatings between the steps of contacting;(g) heating the coated reticulated substrate at a time and temperature sufficient to pyrolyze any organic components; and(h) sintering the coated reticulated substrate to form a ceramic or metal or composite reticulated article.22. A process according to claim 21, wherein the binder is a polyacrylate emulsion.23. A process according to claim 21, wherein the binder is present in the dispersion in an amount of at least 50% by volume based on the entire volume of the solid components of the dispersion following drying.24. A process according to claim 21, wherein the substrate is compliant.25. A process for producing a rigid reticulated article, comprising:(a) providing a first dispersion comprising zirconia powder, a binder, and a solvent;(b) providing a reticulated substrate which has open, interconnected porosity;(c) contacting the reticulated substrate with the first dispersion to coat the substrate with the dispersion to form a first coating;(d) drying the coated reticulated substrate;(e) contacting the coated reticulated substrate with a second dispersion comprising calcium phosphate ceramic, a binder and a solvent to form a second coating over the first coating;(f) drying the second coating;(g) heating the coated reticulated substrate at a time and temperature sufficient to pyrolyze any organic components; and(h) sintering the coated reticulated substrate to form a composite reticulated article.26. A process according to claim 25, wherein the first dispersion further comprises the calcium phosphate ceramic.27. A process according to claim 26, wherein the calcium phosphate ceramic is hydroxyapatite calcium phosphate ceramic.