Porous polymeric media (polymer foams) are utilized in a wide range of applications, such as thermal and mechanical insulators, solid supports for catalysis, and medical devices. A process for the production of polymer foams has been developed. This process, which is applicable to a wide range of polymers, uses a hydrocarbon particulate phase as a template for the precipitation of the polymer phase and subsequent pore formation. The use of a hydrocarbon template allows for enhanced control over pore structure, porosity, and other structural and bulk characteristics of the polymer foam. Polymer foams with densities as low as 120 mg͞cc, porosity as high as 87%, and high surface areas (20 m 2 ͞g) have been produced. Foams of poly(L-lactic acid), a biodegradable polymer, produced by this process have been used to engineer a variety of different structures, including tissues with complex geometries such as in the likeness of a human nose.hydrocarbon porogen ͉ tissue engineering ͉ drug delivery P olymeric foams are utilized in a range of applications such as mechanical dampeners, thermal, acoustic, and electrical insulators, solid supports for catalysis and separations, and medical devices (1-9). Macroporous polymeric foams have been produced by dispersion of a gaseous phase in a fluid polymer phase, leaching of a water-soluble inorganic fugitive phase, phase separation, polymer precipitation, particle sintering, extrusion, and injection molding (1, 2, 10). However, these processes do not generally offer optimal control over pore structure (cell diameter and pore interconnectivity) and bulk characteristics (density, void volume, mechanical and electrical properties) (11).It occurred to us that, by combining two distinct foaming processes, (i) leaching of a fugitive phase with (ii) polymer precipitation, one could attain enhanced control over both porosity and bulk properties of the polymer foam. This was achieved by using a non-water-soluble particulate hydrocarbon fugitive phase derived from waxes, which allowed for the formation of pores with concomitant precipitation of the polymer phase. The macroporosity of the polymer foam was determined by the hydrocarbon fugitive phase (porogen), which also functioned as a template for the rapid precipitation of the polymer. Bulk properties of the foam could be manipulated independently of the macroporosity and pore size by incorporation of inorganic and organic fillers into the highly viscous polymer phase.The process is applicable to a wide range of polymer systems including water-soluble polymers, as long as the following conditions are satisfied: (i) the hydrocarbon porogen is extracted below the melting temperature of the polymer, to ensure isotropy in the properties of the resulting foam; (ii) the polymer has good solubility (at least 100 mg͞ml) in a solvent that is a poor solvent for the porogen, to obtain a viscous polymer solution wherein the porogen can be distributed uniformly; and (iii) the polymer has a molecular weight of at least 40,000, to ensure structural sta...