Biocompatible porous materials and methods of manufacture and use

A method of making a biocompatible open or semi-open celled construct for medical applications, the method comprising:

• submerging an open or semi-open celled polyurethane foam template into a silicone dispersion to expose the polyurethane foam template to the silicone dispersion, the polyurethane foam template comprising a plurality of template struts that define a plurality of template pores,
• allowing the silicone to pass into the plurality of template pores;
• removing at least some of the silicone dispersion from the plurality of template pores;
• forming a construct that includes a plurality of construct struts that define a plurality of construct pores, wherein forming the construct comprises curing the silicone to form a conformal silicone coating on the plurality of template struts,
• the plurality of construct struts having a thickness from 30 microns to 90 microns,
• the conformal silicone coating having a thickness from 1 micron to 20 microns, and
• wherein the construct is 80-98% open pore.