Pu Han

Assistant Research Scientist,

ENGR School of Manufacturing Systems and Networks - Hsu Research Group - JM

[email protected]

Mail code: 6480

Campus: Poly
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Long Bio

Pu Han, an Assistant Research Scientist, is a leading figure in the field of advanced manufacturing and engineering. His primary focus lies in process development aimed at addressing real-world manufacturing challenges. His research revolves around the process sciences and material processing of 3D printing technologies, specifically targeting properties enhancement and cost reduction.

Han is credited with pioneering LaserFFF (laser-assisted fused filament fabrication), a groundbreaking manufacturing method known for its achievement of strength isotropy and smooth surface finish. This innovation has proven instrumental in significantly reducing costs associated with batch production, prototyping, and even in-space manufacturing and assembly.

Han's contributions have been recognized with prestigious awards, including the $260,000 NEI STC Entrepreneurial Fellowship, awarded for the commercialization potential of LaserFFF technology.

Han obtained his Ph.D. in Mechanical Engineering from the University of Louisville in 2021, following a master’s degree in Materials Science and Engineering from Arizona State University in 2015.

Education

Ph.D. in Mechanical Engineering, University of Louisville

Google Scholar URL

https://scholar.google.com/citations?user=xHbJnTcAAAAJ&hl=en

Research Interests

Additive Manufacturing, Space Manufacturing/Assembly

Publications

Han, P., Torabnia, S., Riyad, M. F., Clark, R., Fonseca, N., & Hsu, K. (2025). In-process laser heating for surface finishing of carbon fiber reinforced nylon in fused filament fabrication. Journal of Reinforced Plastics and Composites, p.07316844251345198. https://doi.org/10.1177/07316844251345198
Han, P., Torabnia, S., Riyad, M. F., & Hsu, K. (2025). Laser-assisted fused filament fabrication for mechanical strength improvement of carbon fiber–reinforced polyether ether ketone. 3D Printing and Additive Manufacturing. (preprint) https://doi.org/10.1089/3dp.2024.0115
Han, P., Riyad, M. F., Torabnia, S., Fonseca, N., Garde, N., & Hsu, K. (2025). Low Power Multi-Mode In-Space Metals and Composites Joining. In AIAA SCITECH 2025 Forum (p. 1782). https://doi.org/10.2514/6.2025-1782
Riyad, M. F., Han, P., Torabnia, S., & Hsu, K. (2025). Thermoacoustic consolidation of metal particles for energy-efficient metal powders recycling in metal additive manufacturing. Journal of Manufacturing Science and Engineering, 147(2). https://doi.org/10.1115/1.4066334
Han, P., Torabnia, S., Riyad, M. F., Thippanna, V., Song, K., & Hsu, K. (2024). In-process laser heating for mechanical strength improvement of FFF-printed PEEK. Progress in Additive Manufacturing, pp.1–10. https://doi.org/10.1007/s40964-024-00833-4
Han, P., Torabnia, S., Riyad, M. F., Bawareth, M., & Hsu, K. (2024). Effect of laser heating on mechanical strength of carbon fiber–reinforced nylon in fused filament fabrication. The International Journal of Advanced Manufacturing Technology, 133(11), pp.6139–6146. https://doi.org/10.1007/s00170-024-14103-8
Han, P., Tofangchi, A., Carr, D., Zhang, S., & Hsu, K. (2023). Enhancing the piezoelectric properties of 3D printed PVDF using concurrent torsional shear strain. Polymers, 15(21), p.4204. https://doi.org/10.3390/polym15214204
Han, P., Zhang, S., Yang, Z., Riyad, M. F., Popa, D. O., & Hsu, K. (2023). In-process orbiting laser-assisted technique for the surface finish in material extrusion-based 3D printing. Polymers, 15(9), p.2221. https://doi.org/10.3390/polym15092221
Han, P., Zhang, S., Tofangchi, A., Izquierdo, J., Torabnia, S., & Hsu, K. (2023). Development and implementation of in-process, orbiting laser-assisted healing technique on fused filament fabrication. The International Journal of Advanced Manufacturing Technology, 127, pp.1517–1524. https://doi.org/10.1007/s00170-023-11576-x
Han, P., Tofangchi, A., Zhang, S., Izquierdo, J. J., & Hsu, K. (2023). Interface healing between adjacent tracks in fused filament fabrication using in-process laser heating. 3D Printing and Additive Manufacturing, 10(4), pp.808–815. https://doi.org/10.1089/3dp.2022.0127
Han, P., Zhang, S., Tofangchi, A., & Hsu, K. (2021). Relaxation of residual stress in fused filament fabrication part with in-process laser heating. Procedia Manufacturing, 53, pp.466–471. https://doi.org/10.1016/j.promfg.2021.06.080
Han, P., Tofangchi, A., Zhang, S., Desphande, A., & Hsu, K. (2020). Effect of in-process laser interface heating on strength isotropy of extrusion-based additively manufactured PEEK. Procedia Manufacturing, 48, pp.737–742. https://doi.org/10.1016/j.promfg.2020.05.107
Han, P., Tofangchi, A., Deshpande, A., Zhang, S., & Hsu, K. (2019). An approach to improve interface healing in FFF-3D printed Ultem 1010 using laser pre-deposition heating. Procedia Manufacturing, 34, pp.672–677. https://doi.org/10.1016/j.promfg.2019.06.195
Tofangchi, A., Han, P., Izquierdo, J., Iyengar, A., & Hsu, K. (2019). Effect of ultrasonic vibration on interlayer adhesion in fused filament fabrication 3D printed ABS. Polymers, 11(2), p.315. https://doi.org/10.3390/polym11020315

Honors / Awards

NEI STC Entrepreneurial Fellowship $260,000.