The focus of this thesis is the critical review of Additive Printing (AP) or 3D-printing, and optimization strategies for the introduction of new materials. During the course of tenure, four classes of solids were investigated to determine the hurdles presented from each system. Specifically, the investigation developed techniques for optimization of ink production, green-film deposition, and laser sintering parameters surrounding the Optomec AJP system (AJP). In the assessment, statistical experimental design, analysis and material characterization techniques have been utilized. Final recommendations disseminate current best practices for new ink and material development, along with factor analysis of input variables for phase and material properties, along with insights for future research of these systems.

The first chapter provides a general introduction to the field of AP. The second chapter focuses specifically on Optomec aerosol-jet process (AJP) techniques, and expands the discussion to process parameters, information concerning the fabrication/characterization procedure followed for each system, and includes: a detailed description of the materials investigated. This is important because printing parameters, optimization, and approach may be divergent for optimization within each strain; and is meant as an aid to resolve some technical issues for future investigators. The third chapter is fully dedicated to the results concerning the fabrication and the characterization of amorphous boron powder to film. Chapter four discusses future research options, ideas and directions. Appendices are provided for any which wish to investigate the orthogonal arrays used, or the combinatorial effects resulting in the attributes of the material system final products.