Additive Manufacturing | MAAL

Additive manufacturing process monitoring and control

Mon, 05 Jan 2026 00:00:00 +0000

This project combines additive-manufacturing process models with the dynamics of the motion platform. Thermal cameras, nozzle cameras, accelerometers, and position sensors provide synchronized data for monitoring and compensation.

Research questions

How can process and machine dynamics be represented in one control-oriented model?
Which visual and thermal signals reveal defects early enough for correction?
How should local and cloud controllers share model-based and data-driven tasks?

Expected outcomes

The project develops in-situ monitoring, extrusion-trajectory compensation, and control strategies that improve dimensional accuracy and process stability.

Continuous-fiber additive manufacturing

Sun, 04 Jan 2026 00:00:00 +0000

Continuous fibers can make additively manufactured components significantly stronger and stiffer, but only when the fiber paths follow the structural demands of the part.

Research scope

Build computationally efficient models of free-form composite parts.
Optimize fiber paths for modulus, strength, mass, cost, and manufacturability.
Translate optimized paths into reliable multi-axis fabrication.
Measure the printed parts and connect observed performance back to the model.

The result is an integrated design-to-fabrication workflow for high-performance composite components.

MECH 6910S · Advanced Additive Manufacturing and Topology Optimization

Sun, 04 Jan 2026 00:00:00 +0000

Instructor:

The course introduces seven state-of-the-art additive manufacturing technologies for different material systems. Students study physical principles, process models, and the effects of process parameters before connecting that knowledge to computer-aided design and manufacturing.

Topology optimization is a central part of the course. Students generate structurally efficient designs based on loads, constraints, product requirements, and manufacturing conditions, then fabricate selected parts using metal selective laser sintering or continuous-fiber additive manufacturing.

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MESF 5580 · Topology Optimization and Additive Manufacturing

Sat, 03 Jan 2026 00:00:00 +0000

Instructor:
Teaching assistant:

This course surveys seven additive manufacturing technologies, their physical principles, process models, and parameter effects. It then introduces design-for-additive-manufacturing practices with an emphasis on topology optimization.

Students learn to generate structurally optimal designs that account for loads, constraints, required product performance, and manufacturing conditions.

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MECH 4000O · Introduction to Additive Manufacturing and Rapid Prototyping

Fri, 02 Jan 2026 00:00:00 +0000

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Teaching assistant:

This course introduces fused deposition modeling, material jetting, selective laser sintering, directed energy deposition, stereolithography, and digital light processing across a range of materials.

Students review CAD/CAM and design principles for additive manufacturing, then gain hands-on experience with continuous-carbon-fiber printers through the design, fabrication, measurement, and testing of parts.

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Student project highlights

Fiber-reinforced fixture

A 3D-printed continuous-fiber fixture.

Fiber-reinforced connector

Design and fabrication of a structural connector.

Fiber-reinforced bearing disk

A lightweight printed bearing component.