Production of monolithic bodies from a porous matrix using low temperature solidification in an additive manufacturing process

A method of producing a monolithic body from a porous matrix comprising:

• providing a layer of a porous matrix having interstitial spaces and comprising at least a first reactant;
• contacting the layer of the porous matrix with an infiltrating medium that carries at least a second reactant;
• allowing the infiltrating medium to infiltrate at least a portion of the interstitial spaces of the layer of the porous matrix under conditions that promote a reaction between the at least first reactant and the at least second reactant to provide at least a first product;
• allowing the at least first product to form and fill at least a portion of the interstitial spaces of the layer of the porous matrix;
• and
• repeating the above steps to produce a monolithic body.

A method of producing a monolithic body from a porous matrix comprising:

• providing a plurality of successive layers of a porous matrix having interstitial spaces and comprising at least a first reactant;
• contacting the plurality of successive layers of the porous matrix with an infiltrating medium that carries at least a second reactant;
• allowing the infiltrating medium to infiltrate at least a portion of the interstitial spaces of the layer of the porous matrix under conditions that promote a reaction between the at least first reactant and the at least second reactant to provide at least a first product;
• and
• allowing the at least first product to form and fill at least a portion of the interstitial spaces of the layer of the porous matrix to form the monolithic body.

A method of producing a monolithic body from a porous matrix comprising:

• providing a first layer of a porous matrix having interstitial spaces and comprising at least a first reactant;
• contacting the first layer of the porous matrix with an infiltrating medium that carries at least a second reactant;
• allowing the infiltrating medium to infiltrate at least a portion of the interstitial spaces of the first layer of the porous matrix under conditions that promote a reaction between the at least first reactant and the at least second reactant to provide at least a first product;
• allowing the at least first product to form and fill at least a portion of the interstitial spaces of the first layer of the porous matrix;
• providing a plurality of successive layers of the porous matrix over the first layer of the porous matrix;
• contacting the plurality of successive layers of the porous matrix with the infiltrating medium;
• allowing the infiltrating medium to infiltrate at least a portion of the interstitial spaces of the successive layers of the porous matrix under conditions that promote a reaction between the at least first reactant and the at least second reactant to provide at least a first product;
• and
• allowing the at least first product to form and fill at least a portion of the interstitial spaces of the first layer of the porous matrix, thereby producing a monolithic body.