Fabrication of resin objects using focused ultrasound waves

A method for fabricating a plurality of resin objects, the method comprising steps:

• (a) irradiating a curable composite at a first location with a focal spot of a focused ultrasound beam,
• the focal spot having an intensity of sound waves at the focal spot that is greater than an intensity of sound waves emanating from a sound wave source,
• the curable composite comprising a porous material having a solid matrix defining pores distributed throughout the solid matrix and a curable composition comprising prepolymers filling the pores,
• wherein the step (a) forms a first cured region of a first polymer within the curable composite so as to provide a first resin object comprising an interpenetrating network comprising the solid matrix of the porous material entangled with the first polymer of the first cured region;
• and
• (b) moving the focal spot and the curable composition relative to one another and irradiating the curable composite with the focal spot at a second location separated from the first location, wherein the step (b) forms a second cured region of the first polymer so as to provide a second resin object comprising another interpenetrating network comprising the solid matrix of the porous material entangled with the first polymer of the second cured region, the second resin object separated from the first resin object by the solid matrix such that the first resin object and the second resin object form a plurality of resin objects separated from one another by the solid matrix,
• wherein the first and second resin objects of the plurality of resin objects are embedded within the porous material and have one or more outer dimensions that are smaller than the porous material,
• and further wherein the pores of the porous material have an average pore size that is smaller than that of the focal spot.