Systems and methods for making porous films, fibers, spheres, and other articles

A method of forming a porous article comprising:

• providing a soluble material in particulate form on a substrate;
• forming a packed region of the soluble particulate material having a plurality of voids in the packed region by passing the soluble particulate material through a vibrating mesh frame, wherein a spacer is between the mesh frame and the substrate, and dimensions of the spacer correspond to a desired thickness of particulates to be dispensed on the substrate, and wherein the mesh frame is coupled to a spring apparatus including:
• a support bar, and
• a plurality of tensioned springs configured such that position of the springs relative to the mesh frame vibrates the mesh frame;
• contacting a flowable polymeric material with at least a portion of the packed region of the soluble particulate material whereby at least a portion of the flowable polymeric material is disposed in at least a portion of the voids in the packed region;
• at least partially solidifying the polymeric material to thereby form an intermediate composite material;
• and
• removing at least a portion of the soluble particulate material from the intermediate composite material to thereby form a porous article.