Manufacturing | MAAL

Design and multi-axis additive manufacturing of lightweight and skin-compatible mesh splints using continuous basalt fiber for rehabilitation

Wed, 30 Dec 2026 00:00:00 +0000

Li, F., Gao, F., Yang, Y., Zhou, Y., Duan, M.*, 2026, “Design and multi-axis additive manufacturing of lightweight and skin-compatible mesh splints using continuous basalt fiber for rehabilitation,” ASME Manufacturing Science and Engineering Conference (MSEC), State College, US.

Property-controllable process planning for multi-axis hybrid manufacturing of complex metal parts

Sun, 27 Dec 2026 00:00:00 +0000

He, D., Hao, J., Lau, T.Y., Huang, L., Chen, Y., Hu, P., Xie, J., Duan, M., Liu, X., Tang, K.*, 2026, “Property-controllable process planning for multi-axis hybrid manufacturing of complex metal parts,” Computers in Industry, 179.

Dynamic mode decomposition-based modeling and toolpath optimization of a robotic single point incremental forming process

Thu, 24 Dec 2026 00:00:00 +0000

Asghar, A., He, S., Hu, P., Duan, M.*, 2026, “Dynamic mode decomposition-based modeling and toolpath optimization of a robotic single point incremental forming process,” Journal of Manufacturing Processes, 167, pp. 507-531.

An efficient cutter-facet model projection method and applications to five-axis tool path computation

Wed, 23 Dec 2026 00:00:00 +0000

Li, X., Hu, P.*, Huang, L., Chen, H., Duan, M., Zhang, X., 2026, “An efficient cutter-facet model projection method and applications to five-axis tool path computation,” International Journal of Advanced Manufacturing Technology.

Bead geometry prediction of directed energy deposition based on spatio-temporal neural network model

Tue, 22 Dec 2026 00:00:00 +0000

Chen, Y., Zhang, W., Wang, Y., Hu, P.*, Duan, M., Fu, Z., Deng, X., 2026, “Bead geometry prediction of directed energy deposition based on spatio-temporal neural network model,” International Journal of Advanced Manufacturing Technology.

Toward a High-Throughput Automated Materials Experimentation Platform: Hybrid-Automata-Inspired Modeling and Equipment Configuration Optimization

Mon, 21 Dec 2026 00:00:00 +0000

Ma, G., Cui, H., Yip, C. Y., Zhang, W., Duan, M., Yang, J., 2026, “Toward a High-Throughput Automated Materials Experimentation Platform: Hybrid-Automata-Inspired Modeling and Equipment Configuration Optimization,” IEEE Transactions on Automation Science and Engineering, 23, 11609-11620.

Flexible industrial robot dynamics and control

Tue, 06 Jan 2026 00:00:00 +0000

Industrial robots change stiffness and vibration behavior with their position and posture. This project establishes dynamic models that capture both joint and link flexibility without making the model too costly to use in control.

Approach

Represent geometrically nonlinear links with strain-based beam elements and modal coordinates.
Identify configuration-dependent vibration from experimental data.
Generate nonlinear filtered B-spline trajectories that suppress motion-induced vibration.
Validate compensation strategies on industrial robotic platforms.

Why it matters

More accurate dynamic models allow robots to move faster while maintaining precision. The same methods support robotic machining, additive manufacturing, and large-reach manipulation.

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.

Contact-force-based closed-loop control of multi-axis additive manufacturing With continuous-fiber-reinforced polymer

Wed, 31 Dec 2025 00:00:00 +0000

Yang, Y., Zhou, Y., Duan, M.*, 2025, “Contact-force-based closed-loop control of multi-axis additive manufacturing With continuous-fiber-reinforced polymer,” ASME International Manufacturing Science and Engineering Conference, Greenville.

Optimal-transport-based geometry modeling for material extrusion additive manufacturing

Wed, 31 Dec 2025 00:00:00 +0000

Chen, S., Liu, S., He, S., Duan, M.*, 2025, “Optimal-transport-based geometry modeling for material extrusion additive manufacturing,” Journal of Manufacturing Process, 154, pp. 236-248.

Additive manufacturing with continuous fiber: a comparison between prepreg and in-situ impregnated fiber on printing accuracy, bonding, and mechanical performance

Tue, 30 Dec 2025 00:00:00 +0000

Xu, Z., He, S., Lou, K., Chen, S., Duan, M.*, 2025, “Additive manufacturing with continuous fiber: a comparison between prepreg and in-situ impregnated fiber on printing accuracy, bonding, and mechanical performance,” ASME International Manufacturing Science and Engineering Conference, Greenville.

Evolving stress-guided continuous fiber path optimization for multi-axis additive manufacturing of composite shells

Tue, 30 Dec 2025 00:00:00 +0000

Yang, Y., Xu, Z., Duan, M.*, 2025, “Evolving stress-guided continuous fiber path optimization for multi-axis additive manufacturing of composite shells,” Additive Manufacturing, 113, pp. 105012.

DED bead geometry and profile prediction with multimodal spatio-temporal neural networks

Mon, 29 Dec 2025 00:00:00 +0000

Zhang, W., Wang, Y., Chen, Y., Deng, X., Wang, Y., Duan, M., Hu, P., Tang, K.*, 2025, “DED bead geometry and profile prediction with multimodal spatio-temporal neural networks,” Additive Manufacturing, pp. 104952.

Cable-driven parallel robot trajectory generation with optimized orientation considering disturbance rejection

Fri, 26 Dec 2025 00:00:00 +0000

Liu, S., Duan, M.*, 2025, “Cable-driven parallel robot trajectory generation with optimized orientation considering disturbance rejection,” Mechanism and Machine Theory, 210, pp. 106016.

Freeform trajectory generation for fiber reinforced polymer composites additive manufacturing with variable-deposition-width

Tue, 23 Dec 2025 00:00:00 +0000

Bi, D., Hu, P., Li, Z., Hao, J., Tang, K., Duan, M.*, 2024, “Freeform trajectory generation for fiber reinforced polymer composites additive manufacturing with variable-deposition-width,” Composites Part A: Applied Science and Manufacturing, 188, pp. 108516.

Continuous fiber path optimization in additive manufacturing: A gradient-based B-spline finite element approach

Tue, 31 Dec 2024 00:00:00 +0000

He, S., Ma, P., Duan, M.*, 2024, “Continuous fiber path optimization in additive manufacturing: A gradient-based B-spline finite element approach,” Additive Manufacturing, 86, pp. 104155.

Design, Manufacturing, and Control of a Cable-Driven Bionic Robotic Hand

Tue, 31 Dec 2024 00:00:00 +0000

Lai, C., Liu, S., Duan, M.*, 2024, “Design, Manufacturing, and Control of a Cable-Driven Bionic Robotic Hand,” IEEE International Conference on Robotics and Biomimetics (ROBIO), Bangkok.

Contact-force-based closed-loop control of shell structure additive manufacturing with continuous-fiber-reinforced polymer composites

Sun, 29 Dec 2024 00:00:00 +0000

Yang, Y., Zhou, Y., Duan, M.*, 2024, “Contact-force-based closed-loop control of shell structure additive manufacturing with continuous-fiber-reinforced polymer composites,” Journal of Materials Processing Technology, 331, pp. 118501.

Dynamic geometric modeling for directed energy deposition process

Sun, 29 Dec 2024 00:00:00 +0000

Zhang, W., Chen, S., Dong, B., Chen, Y., Deng, X., Duan, M., Tang, K.*, 2024, “Dynamic geometric modeling for directed energy deposition process,” ASME International Manufacturing Science and Engineering Conference, Knoxville.

Mechanical and morphological variations of basalt fiber in seawater and a strategy to improve its performance with nanocomposite sizing

Sat, 28 Dec 2024 00:00:00 +0000

Li, M., Li, H., Ahizlane, A., Liang, C., Duan, M., Xing, D., Ma, P.*, 2024, “Mechanical and morphological variations of basalt fiber in seawater and a strategy to improve its performance with nanocomposite sizing,” Construction and Building Materials, 420, pp. 135582.

Continuous fiber path optimization approach in additive manufacturing

Mon, 01 Jan 2024 00:00:00 +0000

Duan, M., and He, S., IP.PA.02094, “Continuous fiber path optimization approach in additive manufacturing,” US Provisional Application 63/635,609 (filed Apr 2024); CN Application 202510097967.4 (filed Jan 2025, published).

In-situ additive manufacturing deposition trajectory monitoring and compensation with thermal camera

Sun, 31 Dec 2023 00:00:00 +0000

Chen, S., Yang, Y., Liu, S., Duan, M.*, 2023, “In-situ additive manufacturing deposition trajectory monitoring and compensation with thermal camera,” Additive Manufacturing, 78, pp. 103820.

Design, manufacturing, modelling, and control of a cable-driven parallel robot for additive manufacturing

Sat, 30 Dec 2023 00:00:00 +0000

Duan, M.*, Feng, J., Liu, S., 2023, “Design, manufacturing, modelling, and control of a cable-driven parallel robot for additive manufacturing,” IEEE International Conference on Automation Science and Engineering (CASE), Auckland.

Strength-enhanced volume decomposition for multi-directional additive manufacturing

Sat, 30 Dec 2023 00:00:00 +0000

Bi, D., Duan, M., Lau, T., Xie, F., Tang, K.*, 2023, “Strength-enhanced volume decomposition for multi-directional additive manufacturing,” Additive Manufacturing, 69, pp. 103529.

A physics-guided data-driven feedforward tracking controller for systems with unmodeled dynamics—applied to 3D printing

Fri, 29 Dec 2023 00:00:00 +0000

Chou, C., Duan, M., Okwudire, C.*, 2023, “A physics-guided data-driven feedforward tracking controller for systems with unmodeled dynamics—applied to 3D printing,” IEEE Access, 11, pp. 14563-14574.

Thermal-image-enabled additive manufacturing process monitoring and extrusion trajectory compensation

Fri, 29 Dec 2023 00:00:00 +0000

Duan, M.*, Chen, S., Yang, Y., 2023, “Thermal-image-enabled additive manufacturing process monitoring and extrusion trajectory compensation,” ASME International Manufacturing Science and Engineering Conference, New Brunswick.

Continuous fiber path optimization in composite additive manufacturing

Thu, 28 Dec 2023 00:00:00 +0000

Duan, M.*, He, S., 2023, “Continuous fiber path optimization in composite additive manufacturing,” ASME International Manufacturing Science and Engineering Conference, New Brunswick.

In-situ additive manufacturing deposition trajectory monitoring and compensation system with thermal camera

Sun, 01 Jan 2023 00:00:00 +0000

Duan, M., Chen, S., and Yang, Y., IP.PA.01890, “In-situ additive manufacturing deposition trajectory monitoring and compensation system with thermal camera,” US Provisional Application 63/505,696 (filed Jun 2023); CN Patent ZL202410710170.2 (issued Sep 2025).

A linear hybrid model for enhanced servo error precompensation of feed drives with unmodeled nonlinear dynamics

Fri, 31 Dec 2021 00:00:00 +0000

Chou, C., Duan, M., Okwudire, C.*, 2021, “A linear hybrid model for enhanced servo error precompensation of feed drives with unmodeled nonlinear dynamics,” CIRP Annals - Manufacturing Technology, 70, pp. 301-304.

Energy optimal control of an over-actuated hybrid feed drive under variable-frequency

Thu, 31 Dec 2020 00:00:00 +0000

Duan, M., Ramani, K. S., Okwudire, C.*, 2020, “Energy optimal control of an over-actuated hybrid feed drive under variable-frequency,” Control Engineering Practice, 100, pp. 104442.

Use of filtered basis splines to compensate servo-induced motion errors

Wed, 01 Jan 2020 00:00:00 +0000

Duan, M., Okwudire, C.E., and Ramani, K.S., “Use of filtered basis splines to compensate servo-induced motion errors,” U.S. Patent 10585414, issued Mar. 2020.

Analytical and low-order numerical modeling of ball-to-ball contact friction in linear ball bearings and ball screws

Tue, 31 Dec 2019 00:00:00 +0000

Lin, B., Duan, M., Okwudire, C.*, 2019, “Analytical and low-order numerical modeling of ball-to-ball contact friction in linear ball bearings and ball screws,” Journal of Tribology, 141, 7, pp. 071401.

An improved analytical model of friction and ball motion in linear ball bearings – with application to ball-to-ball contact prediction

Mon, 31 Dec 2018 00:00:00 +0000

Lin, B., Duan, M., Okwudire, C., Wou, J.S.*, 2018, “An improved analytical model of friction and ball motion in linear ball bearings – with application to ball-to-ball contact prediction,” ASME International Mechanical Engineering Congress and Exposition, Pittsburgh.

Software-based compensation of vibration-induced errors of a commercial desktop 3D printer

Sat, 30 Dec 2017 00:00:00 +0000

Yoon, D., Duan, M., Okwudire, C.*, 2017, “Software-based compensation of vibration-induced errors of a commercial desktop 3D printer,” International Conference on Virtual Machining Process Technology, Montréal.

A simplified analytical model of rolling/sliding behavior and friction in four-point-contact ball bearings and screws

Fri, 29 Dec 2017 00:00:00 +0000

Lin, B., Duan, M., Okwudire, C., Wou, J.S.*, 2017, “A simplified analytical model of rolling/sliding behavior and friction in four-point-contact ball bearings and screws,” ASME International Mechanical Engineering Congress and Exposition, Tampa.

Energy-efficient controller design for a redundantly actuated hybrid feed drive with application to machining

Sat, 31 Dec 2016 00:00:00 +0000

Duan, M., Okwudire, C.*, 2016, “Energy-efficient controller design for a redundantly actuated hybrid feed drive with application to machining,” IEEE/ASME Transactions on Mechatronics, 21, 4, pp. 1822-1834.

Modeling and observer-based compensation of slip in a friction drive for servo positioning

Sat, 31 Dec 2016 00:00:00 +0000

Duan, M., Okwudire, C.*, 2016, “Modeling and observer-based compensation of slip in a friction drive for servo positioning,” International Symposium on Flexible Automation, Cleveland.

A trajectory optimization method for improved tracking of motion commands using CNC machines that experience unwanted vibration

Fri, 30 Dec 2016 00:00:00 +0000

Okwudire, C., Ramani, K. S., Duan, M.*, 2016, “A trajectory optimization method for improved tracking of motion commands using CNC machines that experience unwanted vibration,” CIRP Annals - Manufacturing Technology, 65, 1, pp. 373-376.

Minimum-time cornering for CNC machines using an optimal control method with NURBS parameterization

Thu, 29 Dec 2016 00:00:00 +0000

Duan, M., Okwudire, C.*, 2016, “Minimum-time cornering for CNC machines using an optimal control method with NURBS parameterization,” International Journal of Advanced Manufacturing Technology, 85, pp. 1405-1418.

Energy efficiency and performance optimized control of a hybrid feed drive

Wed, 30 Dec 2015 00:00:00 +0000

Duan, M., Okwudire, C.*, 2015, “Energy efficiency and performance optimized control of a hybrid feed drive,” ASME International Manufacturing Science and Engineering Conference, Charlotte.

Minimum-time cornering for manufacturing machines using optimal control

Wed, 31 Dec 2014 00:00:00 +0000

Duan, M., Okwudire, C.*, 2014, “Minimum-time cornering for manufacturing machines using optimal control,” ASME Dynamic Systems and Control Conference, San Antonio.