The future of manufacturing may very well be printed, layer by layer. A group of six dedicated Mechanical Engineering students at SUNY New Paltz, supported by the AC² Summer Research Program, have just published the results of a two-year study exploring the potential of 3D printing for high-volume production. Their research, presented to the American Society for Engineering Education (ASEE), sheds light on the crucial factors that will determine whether 3D printing can truly revolutionize manufacturing as we know it.
Marco Hermida ’25, Aileen Pastrana ’26, Bianca Bermudez ’25, Shaima Herzallah ’25, Christopher Monvil ’26, and Tenmetey Tetteh-Nartey ’25, under the guidance of then Assistant Professor Ping-Chuan Wang and AC² Director Nancy Campos, delved into the intricacies of 3D printing, also known as additive manufacturing. Their goal was to understand how everyday products could be effectively fabricated using this technology, achieving comparable quality to traditionally manufactured goods.
"Since it’s more efficient to make complicated structures through 3D printing than through traditional manufacturing, this research was beneficial in knowing how a 3D printer can make things we use in our everyday lives with similar quality as a traditionally manufactured product,” explained Hermida.
One of the biggest hurdles in 3D printing lies in ensuring the mechanical integrity of the printed objects. Because the process involves depositing materials layer by layer, weak interfaces can form between these layers, potentially compromising the strength and reliability of the final product. However, advancements in additive manufacturing technology are constantly being developed to address this challenge, paving the way for 3D printing to become a viable alternative for high-volume production.
Over two summers, the student research team worked diligently to overcome these challenges, focusing on improving the strength and reliability of 3D printed structures. Their work involved extensive testing and documentation, culminating in presentations to various communities, including the ASEE.
"We wanted to map out the probability of failure with each printing condition,” said Hermida. “What we found is that properly aligning the printed layers creates the most optimal strength and reliability for mass production.” This key finding offers valuable insights for manufacturers looking to implement 3D printing in their processes.
Hermida and Pastrana had the opportunity to present their research alongside Professor Wang at the annual ASEE Mid-Atlantic fall 2024 Conference. Their presentation was met with enthusiasm and ultimately earned them the prestigious Best Paper Award. The team will travel to Reading, Pennsylvania in March to accept the award at the ASEE’s spring 2025 conference, a testament to their hard work and dedication.
The students benefited from access to the Hudson Valley Additive Manufacturing Center on campus. This resource provided them with the perfect environment to conduct their experiments, exploring 3D printing under a variety of conditions. For Pastrana, this experience provided valuable hands-on learning: "This was a big learning opportunity for me to expand on how I see 3D printing,” she said. “Outside of my classes, this was my first real-world experience in a lab, testing out and making 3D printed products.”
The AC² (AMP & CSTEP Community) Program played a crucial role in making this research opportunity possible. This program connects students from underrepresented backgrounds with academic and professional opportunities in STEM fields. Pastrana emphasized the program's impact: “They’re always encouraging you to apply for internships and take part in opportunities you may have not otherwise known about,” she said. “All the opportunities I’ve had are because of the work they do to uplift minority communities.”
The research conducted by these SUNY New Paltz students offers a promising glimpse into the future of manufacturing. Their findings highlight the importance of precise printing conditions for achieving optimal strength and reliability in 3D printed products. As 3D printing technology continues to advance, research like this will be essential for unlocking its full potential and paving the way for a new era of manufacturing.