Sustainable polymer foaming using high pressure carbon dioxide: a review on fundamentals, processes and applications

In recent years, carbon dioxide (CO2) has proven to be an environmentally friendly foaming agent for the production of polymeric foams. Until now, extrusion is used to scale-up the CO2-based foaming process. Once the production of large foamed blocks is also possible using the CO2-based foaming process, it has the potential to completely replace the currently used foam production process, thus making the world-wide foam production more sustainable. This review focuses on the polymer–CO2-foaming process, by first addressing the principles of the process, followed by an overview of papers on nucleation and cell growth of CO2 in polymers. The last part will focus on application of the process for various purposes, including bulk polymer foaming, the production of bioscaffolds and polymer blends.