Noise pollution critically degrades the quality of human life, and its effects are becoming more severe due to rapid population growth and the development of industry and transportation. Acoustic wave aggregation in the 30–8000 Hz band can have a negative impact on human health, especially following continuous exposure to low-frequency noise. This study investigates the acoustic performance of microcellular foams made of a mixture of brittle and soft materials and their potential use as absorption materials. It is common to use porous materials to improve acoustic properties. Specimens prepared by mixing ceramic and urethane were made into microcellular foamed ceramic urethane by a batch process using carbon dioxide. The specimens were expected to exhibit characteristics of porous sound-absorbing materials. After measuring the acoustic characteristics using an impedance tube, a significant sound-absorption coefficient at a specific frequency was noted, a characteristic of a resonance-type sound-absorbing material. However, the sound-absorption properties were generally worse than those before foaming. Differences based on the size, shape, and structure of the pores were also noted. It will be necessary to check the effects of cellular morphological differences on the absorption properties by controlling the variables of the microcellular foaming process in a future study.

Ceramics are non-metallic inorganic materials fabricated from natural or high-purity raw materials through heating and cooling processes. Urethane is a three-dimensional plastic with both elasticity and chemical resistance; moreover, it is used as a rubber substitute. The use of both materials in various applications is gradually increasing. However, as ceramics and urethane have distinctly different properties, this prompted questions regarding the properties of a material that is fabricated using both materials. Therefore, we studied the characteristics of a composite material fabricated through physical foaming using a batch process. The process was conducted with gas saturation, foaming, cooling, and curing. When a specimen of 2 mm thickness was saturated in 5 MPa of CO₂ for 2 h, the solubility was 6.43%; when foaming was carried out at a temperature of 150 °C in boiled glycerin, the foaming ratio, cell size, cell density, and void fraction were found to be 43.62%, 24.40 µm, 9.1 × 10⁷ cells/cm², and 22.11%, respectively. Furthermore, the volume increased by 102.96%, color changed from dark to light gray, hardness decreased by 24%, thermal diffusivity increased by 0.046 mm²/s at 175 °C, and friction coefficient decreased to 0.203. Thus, the microcellular foamed ceramic urethane exhibits a larger volume, lighter weight, and improved thermal conductivity and friction coefficient.

Traditionally, the microcellular foaming process has aimed to generate uniform cell structures by applying heat uniformly to all surfaces of a polymer. Homogeneous cell distribution is known to enhance the mechanical properties and durability of the final product. However, the ability to engineer a gradient in cell density offers potential advantages for specific functional applications, such as improved sound absorption and thermal insulation. In this study, a controlled thermal gradient was introduced by heating only one side of a fully CO₂-saturated poly(methyl methacrylate) (PMMA) specimen. This approach allowed for the formation of a cell density gradient across the sample thickness. The entire process was conducted using a solid-state batch foaming technique, commonly referred to as the microcellular foaming process. A one-sided heating strategy successfully induced a spatial variation in cell morphology. Furthermore, a coalescence function was developed to account for cell merging behavior, enabling the construction of a predictive model for local cell density. The proposed model accurately captured the evolution of cell density gradients under asymmetric thermal conditions and was validated through experimental observations, demonstrating its potential for precise control over foam structure in saturated PMMA systems.

This study investigates the modeling and experimental validation of cell morphology in microcellular-foamed polycaprolactone (PCL) using supercritical carbon dioxide (scCO₂) as the blowing agent. The microcellular foaming process (MCP) was conducted using a solid-state batch foaming process, where PCL was saturated with scCO₂ at 6 to 9 MPa and 313 K, followed by depressurization at a rate of −0.3 and −1 MPa/s. This study utilized the Sanchez–Lacombe equation of state and the Peng–Robinson–Stryjek–Vera equation of state to model the solubility and density of the PCL-CO₂ mixture. Classical nucleation theory was modified and combined with numerical analysis to predict cell density, incorporating factors such as gas absorption kinetics, the role of scCO₂ in promoting nucleation, and the impact of depressurization rate and saturation pressure on cell growth. The validity of the model was confirmed by comparing the theoretical predictions with experimental and reference data, with the cell density determined through field-emission scanning electron microscopy analysis of foamed PCL samples. This study proposes a method for predicting cell density that can be applied to various polymers, with the potential for wide-ranging applications in biomaterials and industrial settings. This research also introduces a Python-based numerical analysis tool that allows for easy calculation of solubility and cell density based on the material properties of polymers and penetrant gases, offering a practical solution for optimizing MCP conditions in different contexts.

Four-dimensional (4D) printing adds the dimension of time to 3D-printed specimens, causing movement when external stimuli are applied. This movement enables applications across various fields, including the soft robotics, aerospace, apparel, and automotive industries. Traditionally, 4D printing has utilized special materials such as shape-memory polymers (SMPs) or shape-memory alloys (SMAs) to achieve this movement. This study explores a novel approach to 4D printing by applying microcellular foaming processes (MCPs) to 3D printing. This study primarily aims to design and fabricate patterned specimens using common materials, such as PLA, through 3D printing and to analyze their dynamic behavior under various foaming conditions. To demonstrate the potential applications of this technology, the degree of bending was measured by controlling the patterning and foaming conditions. The 3D-printed specimens with microcellular foaming exhibited predictable deformations owing to the asymmetric expansion caused by differential gas saturation. The results confirm that 4D printing can be realized using conventional materials without the need for smart materials and can introduce foaming processes as a new external stimulus. This study highlights the potential of combining 3D printing with microcellular foaming for advanced 4D printing applications.

In previous studies, difficulties were encountered in measuring changes within high-pressure vessels owing to limitations such as sensor connectors and sensor failures under high-pressure conditions. In addition, polymer–gas mixtures experience instantaneous gas desorption upon exiting high-pressure vessels owing to pressure differentials, leading to measurement errors. In this study, a device using magnetic sensors was developed to measure the real-time changes in gas-saturated polymers inside pressure vessels. Experiments on polymethyl methacrylate gas adsorption were conducted with parameters including pressure at 5 MPa and temperatures ranging from −20 to 40 °C for 60 and 180 min. It was observed that at −20 °C, the maximum magnetic field force density and deflection were 391.53 μT and 5.83 mm, respectively, whereas at 40 °C, deflection did not occur, with a value of 321.79 μT. Based on gas saturation experiments, a new model for deflection in high-pressure atmospheres is proposed. Additionally, an ANSYS analysis was conducted to predict the changes in Young’s modulus based on gas saturation. In previous studies, mechanical properties were measured outside the pressure vessel, resulting in an error due to a pressure difference, while the proposed method is characterized by the ability to directly measure polymer behavior according to gas saturation in high-pressure vessels using a magnetic sensor in real time. Therefore, it is possible to predict polymer behavior, making it easy to control variables in high-pressure polymer processes.