Hybrid Additive Manufacturing: Role of AM in advancing traditional manufacturing methods

In this seminar, we will discuss recent advancements in AM and how AM can be seamlessly integrated with other manufacturing methods

Guha Manogharan
Emmert H. Bashore Faculty Development Associate Professor of Mechanical Engineering, The Pennsylvania State University

Monday, Feb 26
12:30 - 1:30 PM Eastern Time   (Time change to 12:30 start)
Location: Callaway/GTMI bldg.,
Room 114

Lunch provided for in-person attendees, (registration not required).

If you can’t join us in-person, Zoom link: https://gatech.zoom.us/j/97918374814?pwd=QTk5TDFDb25OeWd4L3JwU2RtbzcrUT09


In this seminar, we will discuss recent advancements in AM and how AM can be seamlessly integrated with other manufacturing methods, i.e., Hybrid AM to address major challenges in two different application domains: (1) Industrial (e.g., aerospace, and defense), and (2) Orthopaedics.


(1) Industrial - Over 90% of all manufactured goods and machinery use a cast part. Sand casting is a manufacturing process that dates back to 7000 BC and accounts for 70% of all cast parts. Sand casting has several critical applications in a variety of sectors including defense, energy, aerospace and automotive. According to American Foundry Society (AFS), you are always within 10 feet of cast part (e.g., automotive engines, valves, manifolds). However, conventional sand casting is regarded as a process of uncertainty due to its tendency to render higher scrap rates even in completely controlled processing environments. Casting defect analysis shows that over 90% of casting defects occur due to improper gating and feeding systems. This talk will first present a novel approach to rethink the design principles for: (a) sand cast parts and (b) gating and feeding systems to reduce defects through 3D sand-printing. Results from numerical analysis, computational melt flow simulations and experimental evaluation show that 3D Sand-Printing can lower melt flow turbulence in castings which reduces casting defects (35% reduction) and improves as-cast mechanical properties (15% increase in as-cast strength)

(2) Orthopaedics - Advancements in digitally driven design and manufacturing is driving a new generation of medical implants and meta-biomaterials to address some of the critical clinical challenges, particularly in orthopaedics. This new class of biomimetic design offers multiple advantages, including: (a) greater control over tailoring the mechanical properties, (b) larger pore space that promotes bone ingrowth and vascularization, and (c) greater effective surface area which could be leveraged for bio-functionalization and infection prevention. Bio-mechanical responses of novel designs in AM porous biomaterials that exhibit nature-inspired geometries will be presented. Finally, morphological, and topological responses of these AM biomimetic porous biomaterials are presented to evaluate their structure–function relationships as well as success in mimicking different bio-mechanical properties of human bone. 


Guha Manogharan, Penn State Department of Materials Science and Engineering. Dr. Guha Manogharan is the Emmert H. Bashore Faculty Development Associate Professor of Mechanical Engineering at The Pennsylvania State University – University Park. He is the Co-Director of CIMP-3D (Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) and also heads the Systems for Hybrid – Additive Processing Engineering - The SHAPE Lab which focuses on additive and hybrid manufacturing with an emphasis on biomedical, defense and aerospace applications. Dr. Manogharan received his Ph.D. (2014) and M.S. (2009) from North Carolina State University. He has received the 2022 ASME ECLIPSE award, and several young investigator awards (2021 ASTM, 2020 NSF CAREER, 2018 FAME Jr., 2017 SME Outstanding Young Manufacturing Engineer Award and 2016 IISE Outstanding Young Investigator by Manufacturing and Design Division). His current work is supported by NSF, DoE, ONR, AFRL and Manufacturing PA.