Abstract: The preparation of three dimensional skeletal structures using the step of deforming rounded beads to form a mold or matrix is described. A filler material is introduced and then rigidified to form the skeletal structure. The deformable beads are composed of materials which deform upon compression or expansion due to pressure from adjacent beads and included, for instance, metals, waxes, salts, polymers, and ceramic compositions in their plasticly deformable states. The filler material which rigidifies to form the skeletal structure can be composed of solidifiable materials such as metals, polymers, or ceramic compositions. The solid material volume of the skeletal structure so formed upon removal of the beads is between about two percent (2%) to twenty percent (20%) of a corresponding volume of a non-skeletal solid material.

Abstract: The preparation of three dimensional skeletal structures using the step of deforming rounded beads to form a mold or matrix is described. A filler material is introduced and then rigidified to form the skeletal structure. The deformable beads are composed of materials which deform upon compression or expansion due to pressure from adjacent beads and included, for instance, metals, waxes, salts, polymers, and ceramic compositions in their plasticly deformable states. The filler material which rigidifies to form the skeletal structure can be composed of solidifiable materials such as metals, polymers, or ceramic compositions. The solid material volume of the skeletal structure so formed upon removal of the beads is between about 2% to 20% of a corresponding volume of a non-skeletal solid material. The corresponding porosities representing the interconnected void volumes are between about 80% and 98% of a corresponding volume of a non-skeletal solid material.