SIU researchers strengthen metal 3D printed parts

According to Southern Illinois University (SIU) Carbondale, a new $200,000 National Science Foundation Engineering Research Initiation grant is enabling professor Sangjin Jung to design metal 3D printed parts that stay strong even when small defects inevitably occur.

“Real production isn’t perfect,” said Jung. “Instead of pretending defects don’t happen, we build them into the design process and make the part robust anyway. One of AM’s biggest advantages is design freedom.”

AM supports the production of custom, high-performance components for industries such as aerospace and automotive (which require weight reduction and fuel efficiency), medical (for patient-specific implants and prosthetics), and defense and energy (for complex, high-duty parts). “In all these cases, the ability to create tailored, intricate geometries gives AM a clear advantage over traditional methods,” said Jung.

AM part defects can spring from many sources – laser power, scan speed, hatch spacing, recoater wear, or even powder quality. These flaws don’t always show up the same way, which makes performance unpredictable. Current design methods often assume defect-free parts, optimize the geometry, and only then discover real-world issues during testing.

Jung’s team will model the likelihood and impact of defects inside their simulations, then optimize the design to be defect-tolerant from the start. The goal is to reduce trial-and-error in the lab and deliver parts that perform reliably in real manufacturing conditions.

AM market growth depends on proving consistent, certifiable performance at scale. If designs can tolerate real-world variability, manufacturers can move more parts from pilot runs to true serial production – with confidence.

The grant strengthens SIU’s design for additive manufacturing (DFAM) capabilities by leveraging the university’s metal 3D printing facilities. Students will work on interdisciplinary projects that blend simulation, optimization, and hands-on printing, gaining experience that translates directly to industry needs. Lessons learned will flow into DFAM-related curricula, modernizing courses and labs.

The team plans workshops and applied projects with local companies, opening doors for capstone collaborations and internships. The result is a talent pipeline for Southern Illinois industries exploring advanced manufacturing – and a clearer route for companies to apply Jung’s research to real AM production problems.

“The research simulates how real-world defects affect performance and then refines the design accordingly,” said Jung. “This will dramatically cut costly experimental iterations while producing designs that align with real manufacturing conditions.”