Abstract
A processing method is described for the preparation of controllable macroscopic architectures in open-cell porous magnesium (Mg). Various macroscopic architectures were devised with computer aided design (CAD). The CAD models were then fabricated as positive templates by 3D printing using an acrylic polymer. The polymer templates could be infiltrated using a specially formulated sodium chloride (NaCl) slurry. Complete removal of the polymer then resulted in a negative NaCl template that was infiltrated with liquid Mg. Optimization of the parameters for the processing of the negative NaCl template was achieved by initially investigating the effect of sintering conditions on the microstructure and mechanical properties of bulk NaCl. Subsequent removal of the NaCl by solvent washing results in Mg with ordered porosity that faithfully reproduced the macroscopic features of the CAD models. The dimensions of the macroscopic features of the positive polymer and NaCl templates were compared to assess the accuracy of replication.