Kai Castillo
Aerospace engineering
Hometown: Mesa, Arizona, United States
Graduation date: Spring 2028
Additional details: First-generation college student
FURI | Spring 2026
Optimization of Powder Bed Fusion of Pure Copper
Additive manufacturing techniques such as laser powder bed fusion (LPBF) enable the fabrication of complex metal components; however, processing pure copper remains challenging due to its high reflectivity and thermal conductivity. These properties can cause poor energy absorption, incomplete melting, and defects such as porosity, which degrade thermal and electrical performance. This project investigates how different process parameters affect the thermal properties of pure copper. Understanding these effects will help identify conditions that produce high-quality copper components, supporting improved performance in applications such as electronics, energy systems, and aerospace engineering.
Mentor: Leila Ladani
It’s hip to be square.
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