A light-weight material and a method for producing a light-weight material use removable forms to produce an array of interconnected voids within the material. The forms include a plurality of spaced apart and adjoining blocks onto which the material is deposited, and the blocks are constructed of a
A light-weight material and a method for producing a light-weight material use removable forms to produce an array of interconnected voids within the material. The forms include a plurality of spaced apart and adjoining blocks onto which the material is deposited, and the blocks are constructed of a material that may be desolidified, such as by vaporization, to remove the blocks from the material, leaving behind a network of interconnected voids.
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1. A method for producing a material having voids therein, the method comprising: depositing a first layer of shaped members on a surface such that each shaped member is in physical contact with at least another of the shaped member of the first layer, whereineach of the shaped members comprises at
1. A method for producing a material having voids therein, the method comprising: depositing a first layer of shaped members on a surface such that each shaped member is in physical contact with at least another of the shaped member of the first layer, whereineach of the shaped members comprises at least one cyanoacrylate polymer;depositing a first layer of matrix on the first layer of shaped members, wherein the first layer of matrix comprises a first type of material;heating the first layer of shaped members and the first layer of matrix such that the cyanoacrylate polymer is vaporized; andremoving the vaporized cyanoacrylate polymer from the material to leave behind voids within the material. 2. The method of claim 1, wherein: heating comprises heating the first layer of shaped members and the first layer of matrix under vacuum to a temperature sufficient to depolymerize the cyanoacrylate polymer to cyanoacrylate monomers and to vaporize the cyanoacrylate monomers. 3. The method of claim 2, further comprising collecting and recycling the vaporized cyanoacrylate monomers. 4. The method of claim 1, wherein depositing the first layer of shaped members comprises depositing cyanoacrylate polymer droplets onto the surface such that the droplets combine and cure to form the first layer of shaped members, wherein the shaped members are in a predetermined pattern. 5. The method of claim 1, wherein depositing the first layer of shaped members comprises: etching parallel aligned grooves in the surface to receive the shaped members thereon; anddepositing the shaped members in the grooves to form parallel rows of adjoining shaped members. 6. The method of claim 4, wherein: depositing droplets of the cyanoacrylate polymer onto the surface comprises printing of the predetermined pattern by propelling the droplets of the cyanoacrylate polymer from inkjet printing head nozzles onto the surface. 7. The method of claim 1, wherein the method further comprises: depositing a second layer of shaped members on the first layer of matrix prior to heating the first layer of shaped members and the first layer of matrix, wherein each of the shaped members of the second layer is in physical contact with at least another of the shaped members of the second layer; anddepositing a second layer of matrix on the second layer of shaped members, wherein the second layer of matrix comprises a second type of material. 8. The method of claim 7, wherein the method further comprises repeating the steps of depositing the second layer of shaped members and depositing the second layer of a matrix until a desired thickness of material is obtained. 9. The method of claim 1, wherein: depositing the first layer of shaped members comprises depositing cuboid shaped members having a length dimension in a first range from about 2 micrometers to about 10 micrometers, a width dimension in a second range from about 1 micrometer to about 5 micrometers, and a thickness dimension in a third range from about 1 micrometer to about 5 micrometers, and each of the cuboid shaped members is coupled with an adjacent cuboid shaped member by a spacer portion; anddepositing the first layer of matrix comprises depositing the first layer of matrix having a thickness in a fourth range from about 1 micrometer to about 5 micrometers. 10. A method for producing a multi-layered material with voids on a multi-station conveyor system comprising a form placement station and a matrix material deposition station pairing for each layer of the multi-layer material and the method comprises: in a first form placement station, depositing a first form layer of shaped members on a carrier to carry the first form layer along the conveyor system, wherein each of the shaped members comprises at least one cyanoacrylate polymer;conveying the carrier with the first form layer to a first deposition station;depositing a first layer of matrix material on the first form layer at the first deposition station;conveying the carrier from the first deposition station to a second form placement station;depositing a second layer of shaped members on the first layer of matrix material to form a second form layer at the second form placement station;conveying the carrier from the second form placement station to a second deposition station;depositing a second layer of matrix material on the second form layer at the second deposition station;repeating the steps of depositing the second layer of shaped members and depositing the second layer of matrix material until a desired thickness of the multi-layered material is obtained;conveying the carrier with the multi-layered material from the second deposition station to a heating and vacuum chamber; andvaporizing and removing cyanoacrylate polymer to form the multi-layered material with voids. 11. The method of claim 1, wherein: depositing the first layer of matrix on the first layer of shaped members comprises spraying or vapor depositing the first layer of matrix, wherein the first layer of matrix comprises a first type of material selected from the group consisting of metals, polymers, ceramics, resins, and combinations thereof anddepositing the first layer of shaped members comprises depositing the shaped members comprising the cyanoacrylate polymer selected from the group consisting of polymethyl cyanoacrylate, polyethyl cyanoacrylate, polypropyl cyanoacrylate, polybutyl cyanoacrylate, polyoctyl cyanoacrylate, and combinations thereof. 12. The method of claim 1, wherein the depositing the first layer of shaped members comprises depositing an array of individual shaped members with each of the individual shaped members in physical contact with at least another of the individual shaped members to form a contiguous array of individual shaped members. 13. The method of claim 7, wherein depositing the second layer of matrix comprises depositing the second layer of matrix wherein the second type of material is substantially similar to the first type of material. 14. The method of claim 7, wherein depositing the second layer of matrix comprises depositing the second layer of matrix wherein the second type of material is different from the first type of material. 15. A method for producing a material having voids therein, the method comprising: depositing cyanoacrylate polymer droplets onto a surface such that the droplets combine and cure to form a first layer of shaped members in the predetermined pattern of shaped member;depositing a first layer of matrix on the first layer of shaped members, wherein the first layer of matrix comprises a first type of material;heating the first layer of shaped members and the first layer of matrix such that the cyanoacrylate polymer is vaporized; andremoving the vaporized cyanoacrylate polymer from the material to leave behind voids within the material. 16. The method of claim 15, wherein: depositing the cyanoacrylate polymer droplets comprises depositing the cyanoacrylate polymer selected from the group consisting of polymethyl cyanoacrylate, polyethyl cyanoacrylate, polypropyl cyanoacrylate, polybutyl cyanoacrylate, polyoctyl cyanoacrylate, and combinations thereof anddepositing the first layer of matrix on the first layer of shaped members comprises spraying or vapor depositing the first layer of matrix, wherein the first layer of matrix comprises the first type of material selected from the group consisting of metals, polymers, ceramics, resins, and combinations thereof. 17. The method of claim 15, wherein: heating comprises heating the first layer of shaped members and the first layer of matrix under vacuum to a temperature sufficient to depolymerize the cyanoacrylate polymer to cyanoacrylate monomers and to vaporize the cyanoacrylate monomers. 18. The method of claim 15, wherein the method further comprises: depositing a second layer of shaped members on the first layer of matrix prior to heating the first layer of shaped members and the first layer of matrix, wherein each of the shaped member of the second layer is in physical contact with at least another of the shaped members of the second layer; anddepositing a second layer of matrix on the second layer of shaped members, wherein the second layer of matrix comprises a second type of material.
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