Towards tunable polymer foam fabrication: A case study to advance green materials development in limited data scenarios.

Early phases of green material development can be accelerated by identifying driving factors that control material properties to understand potential tradeoffs. Full investigation of fabrication variables is often prohibitively expensive. We propose a pared‐down design of experiments (DOE) approach to identify driving variables in limited data scenarios using tunable polydimethylsiloxane (PDMS) foams made via sacrificial templating as an example system. This new approach systematically determines the dependencies of porosity, transparency, and fluid flow by varying the template particle size and packing while using a more sustainable solvent. Factor screening identified template particle size and packing density as the driving factors for foam performance by controlling pore size and interconnectivity. The framework developed provides a robust, foundational understanding of how to green and tune a novel material's properties using an efficient and effective exploration of the design space. Recommendations for applying this method to a broad suite of experiments are provided. [ABSTRACT FROM AUTHOR]