2025 ASEE Annual Conference & Exposition

Integrating Computer-Aided Manufacturing Users with Directed Energy Deposition Guidelines

Presented at Manufacturing Division (MFG) Technical Session 5

Convergent manufacturing platforms integrate heterogeneous systems (such as additive, subtractive, and inspection processes) more seamlessly throughout the manufacturing process. However, this leaves operators reliable for several processes on platforms that are still emerging with limited knowledge transfer readily available. The lack of process guidance, especially directed energy deposition (DED) additive manufacturing, hinders computer-aided manufacturing (CAM) users from taking full advantage of their design space. CAM users require an intuitive understanding of additive toolpath strategy performance which is not well-represented in current training practices, leading to programming delays that often run over the estimated project timelines. Therefore, the objective of this study is to understand how to better equip designers through communicating the CAM strategy impact on parts in a convergent DED process. An outline of DED guidelines was created and tested on experienced users of CAM technology who are new to DED process development. Participants took part in three modules overviewing DED convergent manufacturing. These modules combined in-depth system overviews, visual presentations, and hands-on part production and judgement. Survey feedback after completing the modules provide self-reported confidence to produce DED-focused CAM programs as well and feedback on the individual training modules. This feedback will drive the next iteration of presenting DED convergent manufacturing guidelines for CAM users to improve awareness of manufactured part quality and the corresponding necessary process modifications.

Authors

Dr. Kenton Blane Fillingim Oak Ridge National Laboratory [biography]

Dr. Kenton Blane Fillingim is R&D staff for human factors in advanced manufacturing within the Manufacturing Sciences Division at Oak Ridge National Laboratory. His research at ORNL's Manufacturing Demonstration Facility focuses on process development to accelerate the industrialization of directed energy deposition (DED) convergent manufacturing platforms. He aims to improve the user experience and increase the success of designers and operators in convergent manufacturing environments. Blane received his B.S. in Mechanical Engineering from the University of South Alabama, and his M.S. and Ph.D. degrees in Mechanical Engineering from the Georgia Institute of Technology.
Dr. Lauren Heinrich Oak Ridge National Laboratory [biography]

Dr. Lauren Heinrich is a technical staff member who provides research support with her experience in hybrid manufacturing in the Manufacturing Science Division at Oak Ridge National Laboratory. She received her bachelor's in mechanical engineering from Lipscomb University in 2020 then completed her master's degree in mechanical engineering with a focus on wire arc additive manufacturing processing from Georgia Institute of Technology in 2022. Heinrich started at ORNL in 2022 and her work at the Department of Energy's Manufacturing Demonstration Facility consists of utilizing hybrid manufacturing, a combination of additive and subtractive (machining) manufacturing, to further support manufacturing in the tool and die, aerospace, energy systems, and automotive industries.
Dr. Ashley Gannon Oak Ridge National Lab [biography]

Dr. Ashley Gannon is a Research and Development Professional specializing in simulation and visualization at Oak Ridge National Laboratory. Ashley's work focuses on combining finite element simulations, in-situ monitoring, and toolpath optimization strategies to optimize additive manufacturing processes by reducing residual stress and geometric distortion in printed parts. Ashley earned her Ph.D. in Computational Science from Florida State University, her Master's in STEM teaching, and Bachelor's degrees in Chemical & Biomedical Engineering and Biological Sciences.
Dr. Thomas Feldhausen Oak Ridge National Laboratory [biography]

Dr. Thomas Feldhausen is a research staff member in the Manufacturing Science Division at Oak Ridge National Laboratory in addition to being a joint faculty member of the University of Texas at El Paso as a research assistant professor in the department of Aerospace and Mechanical Engineering. He received his bachelor’s and master’s degree in mechanical engineering from Kansas State University, with a focus on curriculum development for mechanical engineering education, and a Ph.D. degree from the Georgia Institute of Technology in the field of hybrid (additive and subtractive) manufacturing. Thomas started at ORNL in 2019 and has been the technical lead for hybrid manufacturing. Before working at ORNL, Thomas worked at Honeywell Federal Manufacturing and Technologies in Kansas City where he focused on multi-axis additive techniques for direct ink-write technologies.

Dr. Feldhausen has made significant contributions to the field of additive manufacturing with his innovative research at the Department of Energy’s Manufacturing Demonstration Facility. His research utilizes hybrid manufacturing, a combination of additive and subtractive (machining) manufacturing, to provide industrial solutions for component repair, tooling and tooling repair, advanced energy systems, aerospace, and automotive applications.

Dr. Feldhausen’s work has been recognized with numerous awards, including an Outstanding Young Manufacturing Engineering Award by the Society of Manufacturing Engineers, selected as a 30 under 30 individual by the Society of Manufacturing Engineers, National Nuclear Security Administration Defense Program Award of Excellence, R&D 100 award winner, attendee of the Grainger Foundation U.S. Frontiers of Engineering symposium hosted by the National Academy of Engineering, and currently serves on the technical committee for manufacturing processes for the American Society of Mechanical Engineer’s Manufacturing Engineering Division.

Currently, Dr. Feldhausen is leading ORNL’s portfolio on the industrialization of emerging manufacturing platforms, which aims to develop advanced systems that will support DOE’s efforts in establishing a strong and resilient domestic supply chain. Dr. Feldhausen’s enthusiasm and technical expertise have positioned him as a leading figure in the field of additive manufacturing, and his work has the potential to revolutionize the manufacturing industry.

Note

The full paper will be available to logged in and registered conference attendees once the conference starts on June 22, 2025, and to all visitors after the conference ends on June 25, 2025

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