Woodruff School of Mechanical Engineering



Design Challenges & Research Opportunities in Additive Manufacturing


Prof. Tim Simpson


Penn State University


Monday, November 2, 2015 at 2:00:00 PM


MARC Building, Room 114


David Rosen


Additive manufacturing may be as disruptive to manufacturing as the Industrial Revolution was over a hundred years ago. Additive manufacturing frees us from many of our design constraints and provides the capability to produce novel and intricate geometries never before possible. The opportunities that this is creating in fields ranging from aerospace and energy to medical and oil and gas is unprecedented, but there are real obstacles that must be overcome. The potential for warping, cracking, and distortion necessitates a careful understanding of the underlying physics occurring during additive manufacturing of metallic components. When fabricating metal parts, additive manufacturing is as much about producing a finished part as it is about making a material given the impact that powder properties and processing parameters can have on the final microstructure and resulting material properties. In this talk, I will discuss the design challenges and research opportunities in additive manufacturing and summarize the activities in Penn State's Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D), which serves as the DARPA Open Manufacturing Program’s Additive Manufacturing Demonstration Facility (MDF). CIMP-3D seeks to (1) advance enabling technologies required to successfully implement AM technology for critical components and structures, (2) provide technical assistance to industry through selection, demonstration, and validation of AM technology as an honest broker, and (3) promote the potential of AM technology through training, education, and dissemination of information. CIMP-3D also provides Penn State's interface to America Makes, the National Additive Manufacturing Innovation Institute (NAMII), which is charged with transitioning additive manufacturing technology to the mainstream U.S. manufacturing sector and enabling significant advancements throughout industry.


Dr. Simpson is a Professor of Mechanical & Industrial Engineering at Penn State University with affiliations in Engineering Design and the College of Information Sciences & Technology. He is also co-Director of CIMP-3D (www.cimp-3d.org). He received his Ph.D. and M.S. degrees in Mechanical Engineering from Georgia Tech in 1998 and 1995, and his B.S. in Mechanical Engineering from Cornell in 1994. He has been PI or Co-PI on over $25M in funding for his research in product family and product platform design, multidisciplinary design optimization (MDO), and additive manufacturing, and he has published over 250 peer-reviewed papers and 2 edited books to date. He teaches courses on Mechanical Design, Industrial Systems Design, Concurrent Engineering, Product Family Design, and Product Dissection. He is a recipient of the ASME Ben C. Sparks Award, the ASEE Fred Merryfield Design Award, and a NSF Career Award. He has received several awards for outstanding research and teaching at Penn State, including the 2007 Penn State President's Award for Excellence in Academic Integration. He is a Fellow in ASME and an Associate Fellow in AIAA. He currently serves on the ASME Design, Manufacturing, and Materials Segment Leadership Team and the ASME Design Engineering Division Executive Committee, and he helped ASME launch the IAM3D Design Challenge and is Chair of the Executive Advisory Committee for ASME's inaugural Additive Manufacturing & 3D Printing Conference, which was held in Boston, MA in early August 2015.