This research develops a new method for high-resolution 3D printing of metals such as copper. Instead of laser melting, ultraviolet light forms hydrogel structures that are chemically transformed into metal. The technique enables finer features, reduced waste, and fabrication of advanced materials for applications including batteries, structural engineering, and manufacturing.

This thesis developed multifunctional 3D-printed scaffolds for repairing critical-size mandibular bone defects. Using bioactive ceramics, surface coatings, and prevascularization strategies, it promoted both osteogenesis and angiogenesis. Results show that combining geometry, materials, and biological signals enables synergistic tissue regeneration, offering less-invasive alternatives to autologous bone grafts.

This research advances metal additive manufacturing by replacing wasteful machining with laser-based powder fusion. Inspired by baking, printed metal parts are optimized through microstructural analysis. The approach produces complex geometries with equal or superior strength and durability while significantly reducing material waste, enabling cleaner, more sustainable manufacturing.

This research improves the reliability of metal 3D-printed parts by studying internal porosity using X-ray computed tomography and extreme value statistics. By modeling the largest, failure-critical pores and accounting for uncertainty and geometry effects, it enables better prediction of fatigue performance in aerospace and medical components.