We present a generic and versatile low temperature route to produce macro-porous bodies with porosity and pore size distribution that are adjustable in a wide range. Capillary suspensions, where the minor fluid is a monomer, are used as pre-cursors. The monomer is preferentially located between the particles, creating capillary bridges, resulting in a strong, percolating network. Thermally induced polymerization of these bridges at temperatures below 100 °C for less than 5 hours and subsequent removal of the bulk fluid yields macroscopic, self-supporting solid bodies with high porosity. This process is demonstrated using methylmethacrylate and hydroxyethylmethacrlyate with glass particles as a model system. The produced PMMA had a molecular weight of about 500.000 g/mol and dispersity about three. Application specific porous bodies, including PMMA particles connected by PMMA bridges, micron-sized capsules containing phase change material with high inner surface, and porous graphite membranes with high electrical conductivity, are also shown.

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In this article, we review recent research in the field of capillary suspensions and highlight a variety of applications in the field of smart materials. Capillary suspensions are liquid-liquid-solid ternary systems where one liquid is only present in a few percent and induces a strong, capillary-induced particle network. These suspensions have a large potential for exploitation, particularly in the production of porous materials since the paste itself and the properties of the final material can be adapted. We also discuss the rheological properties of the suspension and network structure to highlight the various ways these systems can be tuned.

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