Directional Freeze-Casting: A Bioinspired Method to Assemble Multifunctional Aligned Porous Structures for Advanced Applications

Abstract

Herein, the potential of directional freeze-casting techniques as a very generic, green, and straightforward approach for the processing of various functional porous materials is introduced. These materials include 3D monoliths, films, fibers, and microspheres/beads, which are obtained by the assembly of network building blocks originated from cryoassembly of the various aqueous-based systems. The process simply relies on 1) directional freezing of the slurry through contact with a cold surface, 2) maintaining the slurry at the frozen state for a particular time with controlling the freezing parameters and directions, and 3) sublimation of the created ice crystal templates inside the developed structure to translate the ice growth pattern to final porous structure. The materials developed with such a cryogenic process contain a highly complex porous structure, e.g., a hierarchical and well-aligned microstructure in different levels, which renders a high control over the physicochemical and mechanical functionalities. Due to the versatility and controllability of this technique, the process can also be extended for the mimicking of the structures found in natural materials to the bulk materials to assemble bioinspired porous composites with many useful mechanical and physical features. The aim, herein, is to give a brief overview of the recent advances in developing anisotropic porous inorganic, organic, hybrid, and carbonaceous materials with a particular emphasis on materials with biomimicking microstructure using directional ice templating approach and to highlight their recent breakthrough for different high-performance applications.