A method called loose sintering was first introduced to prepare ultrahigh-molecular weight polyethylene (UHMWPE) microporous materials. The pore size was predicted by the face-centered cubic structure model while considering the particles' arrangement and melt. The results showed that the experimental pore diameter was close to that calculated by the present model. The effects of UHMWPE molecular weight, particle diameter, packing density, sintering temperature, and sintering time on pore size, compressive strength, pore diameter distribution, and density were presented. The morphology of micropore and the uniformity of pore distribution were analyzed by scanning electron microscopy and fractal geometry. The results showed that average pore diameter and porosity both increased with the UHMWPE particle diameter while decreased with compressive strength and bulk density. Sintering temperature and sintering time determined whether the heat was redundant to melt the particles. They also determined the pore size and the uniformity. UHMWPE microporous materials could be successfully prepared with suitable processing conditions. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012
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