This master's thesis deals with the challenges of undesirable thermal expansion in lightweight materials. Thermal expansion of parts or components can lead to malfunction or breakdowns of complete systems in demanding environment where a large temperature gradient often exists. This work investigates a class of lightweight materials of which the thermal expansion coefficient can be controlled. Moreover, an additive manufacturing approach to produce these thermal management materials with high fidelity and reliability are critical to reach this goal.

To achieve these two major research objectives analytic predictions, simulations, and measurement of thermal expansion coefficient with respect to temperature changes are conducted. Design and optimization of a high precision multi-material manufacturing apparatus has been conducted, leading to significant increase in production quality including reliability, efficiency, and costs.