| abstract |
The present application relates to a method and flexible cellular foam. A method of making a foamed article (1), such as an article (1, 2) or a foamed part of footwear, comprising forming a structure of interconnected, unfoamed thermoplastic polymer members (30), whereby The thermoplastic polymer members are spaced apart to define openings (12, 22, 32) between the thermoplastic polymer members (30). The structures can be prepared by printing thermoplastic polymer materials with a three-dimensional printer. Heating the thermoplastic polymer member (30) to a first temperature to soften the thermoplastic polymer member (30) and infusing the softened thermoplastic polymer member (30) at a first pressure greater than atmospheric pressure at least an inert gas. The first pressure is sufficient to cause the at least one inert gas to penetrate into the softened thermoplastic polymer member (30). After pouring the inert gas, the pressure is reduced to at least partially foam the thermoplastic polymer member (30). |