Additive Manufacturing is a disruptive technology that is creating a paradigm shift in the manufacturing industry. However, it is still suffering from various setbacks that make it cost prohibitive in many cases, or not reliable enough in others. This thesis describes process improvements, mainly the introduction of ultrasonic excitation, discovered at HKUST through 5 years of research in the Mechanical Engineering Department. These improvements allow for far more excellent mechanical properties and microstructure of manufactured parts. Consequently, they allow for the elimination a lengthy and costly step in Additive Manufacturing: Thermal Post-­Processing, leading to up to 75% cost savings, and up to 65%-time savings. The commercial potential for this innovation is thus very high, and...[ Read more ]

Additive Manufacturing is a disruptive technology that is creating a paradigm shift in the manufacturing industry. However, it is still suffering from various setbacks that make it cost prohibitive in many cases, or not reliable enough in others. This thesis describes process improvements, mainly the introduction of ultrasonic excitation, discovered at HKUST through 5 years of research in the Mechanical Engineering Department. These improvements allow for far more excellent mechanical properties and microstructure of manufactured parts. Consequently, they allow for the elimination a lengthy and costly step in Additive Manufacturing: Thermal Post-­Processing, leading to up to 75% cost savings, and up to 65%-time savings. The commercial potential for this innovation is thus very high, and is showcased through thorough market research, operational plan, and financial projections.