The way in which a perforated structure is formed has attracted much interest in the porous membrane research community. This novel structure gives materials an excellent antifouling property as well as a low operating pressure and other benefits. Unfortunately, the current membrane fabrication methods usually involve multi-step processes and the use of organic solvents or additives. Our study is the first to offer a way to prepare perforated membrane by using a physical foaming technique with CO₂ as the blowing agent. We selected thermoplastic polyurethane (TPU) as the base material because it is a biocompatible elastomer with excellent tensility, high abrasion resistance, and good elastic resilience. Various processing parameters, which included the saturation pressure, the foaming temperature, and the membrane thickness, were applied to adjust the TPU membrane’s perforated morphology. We proposed a possible formation mechanism of the perforated membrane. The as-prepared TPU membrane had good mechanical properties with a tensile strength of about 5 MPa and an elongation at break above 100%. Such mechanical properties make this novel membrane usable as a self-standing filter device. In addition, its straight-through channel structure can separate particles and meet different separation requirements.

The diverse physical appearances and wide density range of polymer bead foams offer immense potential across various applications and future advancements. The multi-scale and multi-level structural features of bead foams involve many fundamental scientific topics. This review presents a comprehensive overview of recent progress in bead foams preparation and molding techniques. Initially, a comparative analysis is conducted among bead foam characteristics of distinct polymers, based on their unique properties. Subsequently, a summary and comparison of molding processes employed for fabricating bead foam parts are provided. Beyond traditional methods like steam-chest molding (SCM) and adhesive-assisted molding (AAM), emerging techniques like in-mold foaming and molding (IMFM) and microwave selective sintering (MSS) are highlighted. Lastly, the bonding mechanisms behind the diverse molding methods are discussed.