HSU Continues Groundbreaking Metal Additive Manufacturing Research

Hardin-Simmons University (HSU) is proud to announce the continuation of its pioneering research project in metal additive manufacturing (AM), also known as metal 3D printing, in collaboration with Pantex, a National Nuclear Security Administration (NNSA) site under the Department of Energy (DOE). This significant research initiative, now entering its fourth phase, originally began six years ago and has been actively pursued at HSU since Dr. Matt Jackson, P.E, Dean of the Holland School of Sciences and Mathematics, and Gabby Bognich, Director of Engineering Research, joined the university in 2022.

Gabby Bognich works with students at HSU.

The metal AM field, although new with its inception about a decade ago and its industrial application starting just five years ago, is rapidly evolving. Unlike traditional 3D printing, which has become relatively commonplace over several decades, metal AM presents unique challenges and opportunities for innovation. One of the primary challenges in this field is the 80% success rate of metal printed parts, which, while adequate for low-risk commercial applications, falls short for high-consequence, critical tasks where public safety is paramount.

Dr. Jackson added, “Recognizing the importance of advancing this technology for applications critical to our nation’s interests, the DOE has shown a keen interest in our research, which focuses on using optical sensors during the print process to detect anomalies and print errors.”

HSU is uniquely positioned in this research. “Our team is also developing computational methods to predict and potentially prevent these flaws, representing a unique advancement in both technology and methodology not being undertaken anywhere else in the world,” explained Dr. Jackson.

In addition to the $750K, 18-month project continuation, the team is equipped with over $1 million worth of advanced equipment provided by Pantex, housed in our state-of-the-art research lab in Abilene Hall.

Abilene Hall is home to HSU’s engineering program.

This project not only advances the field of metal AM but also provides invaluable opportunities for both faculty and students at HSU. By engaging with cutting-edge technology and innovative ideas, students gain unique learning experiences that enhance critical thinking and problem-solving skills, preparing them to excel in industry or further academic pursuits after graduation.

“Research is a unique branch of science and engineering that fosters creativity and innovation, and we want students to be a part of that,” said Gabby Bognich. She went on to say, “Our research assistants will have hands-on, practical experience that translates what they are learning in the classroom to real-world, industry-leading applications. Research opportunities like this should inspire both students and faculty across HSU to continue learning and innovating.”