Sand Casting
Advancing metal casting process via 3D sand printing
Increases casting design complexity, improves mechanical properties, and enables earlier defect identification.
S.H.A.P.E. Lab
Systems for Hybrid-Additive Process Engineering
The mission of the Systems for Hybrid-Additive Process Engineering Lab (SHAPE Lab) is to advance:
- 1.Additive Manufacturing: Design, Material Development and Biomedical Applications
- 2.Hybrid Manufacturing
- 3.Sand-Printing for Metal Casting
Research
Projects across the additive manufacturing landscape.
Research highlights connect students, tools, manufacturing equipment, and publications across additive manufacturing, hybrid manufacturing, binder jetting, biomedical AM, and sand printing for casting.
Sand Casting
Metal Casting
Printed molds, cores, and process design
Printed sand tooling supports complex thermal, geometric, and production-aware casting workflows.
Process Systems
Manufacturing-centered research environments
Students connect design, simulation, lab equipment, and inspection in complete research loops.
Hybrid Manufacturing
Hybrid Manufacturing
Additive Manufacturing + Mass Finishing Hybrid Manufacturing System
Improving metal AM surface finish and cost efficiency through post-processing and characterization.
DfAM
Design for Additive Manufacturing
Novel design rules, lattice structures, and optimization methods for process-aware parts.
Biomedical AM
Patient-specific and orthopedic additive manufacturing
High-fidelity biomedical geometries, biodegradable implants, and controlled scaffold structures.
Team
Guha Manogharan, Ph. D.
Co-Director, CIMP-3D · Associate Professor, Department of Mechanical Engineering
Ph.D., Industrial Engineering, North Carolina State University
M.S., Industrial Engineering, North Carolina State University
B.Tech., Mechanical Engineering, SASTRA University, India
Additive Manufacturing, Hybrid Manufacturing, Design Optimization, CNC Machining and Non-Traditional Machining, Biomedical Applications of AM and Metal Casting.
Ph.D. Students
Andres Bujanda
Research Engineer
Chris Carson
Undergraduate Students
Alumni
Post-Doctoral
Sagar Jalui
Ph.D., Mechanical Engineering, 2024
Alan Burl
Ph.D., Mechanical Engineering, 2025
Ph.D.
Jacklyn Griffis
Ph.D., Mechanical Engineering, 2026
Interfaces in Multi-Material Laser Powder Bed Fusion: Defect Formation and Mitigation
Sagar Jalui
Ph.D., Mechanical Engineering, 2024
AM-driven design innovation: DfAM constraints in adjoint shape optimization for gas turbine applications
Ankit Saxena
Ph.D., Mechanical Engineering, 2024
Systematic design of pressure-actuated adaptive structural cells enabling adaptive mechanical properties in mechanical structures
Philip King
Ph.D., Mechanical Engineering, 2023
Bridging the oldest and newest manufacturing technologies: Additive Manufacturing, Metal Casting, and Internet of Things.
Foxian Fan
Ph.D., Industrial & Manufacturing Engineering, 2023
Evolution of Additive Manufacturing surface morphology during Centrifugal Disc Finishing.
Md Moinuddin Shuvo
Ph.D., Mechanical Engineering, 2023
Improving sustainability of Sand-Casting Processes via novel 3D Mold Designs.
Xi Gong
Ph.D., Mechanical Engineering, 2020
Machining Behavior and Material Properties in Additive Manufacturing of TI-6AL-4V Parts
Maryam Tilton
Ph.D., Mechanical Engineering, 2020
Multi-Objective Design and Characterization of Orthopaedic Implants and Meta-Biomaterials Fabricated via Additive Manufacturing
Masters
Kaitlyn Hartman
M.S. Mechanical Engineering, 2025
Functionally Graded TPMS Lattice Structures Optimized to Improve Mechanical Strength
Mychal Taylor
M.S. Mechanical Engineering, 2024
Power cell packaging using a structural electronics approach
Buket Yilmaz
M.S. Mechanical Engineering, 2024
A review of the interface design in multi-material laser powder bed fusion of metals
Matthew Williams
M.S. Mechanical Engineering, 2024
Multi-axis routing of syringe deposited conductive traces over topology-optimized multi-functional structures
Serah Hatch
M.S. Mechanical Engineering, 2024
A microstructure based machine learning model to predict mechanical properties of LPBF-manufactured 15-5PH stainless steel.
Carson Vath
M.S. Mechanical Engineering, 2024
Development and testing of novel multi-material additive manufacturing systems for embedding wire electronic.
Sandy Karam
M.S. Mechanical Engineering, 2023
Additive Manufacturing of patient-specific high-fidelity and thickness-controlled cerebral aneurysm geometries
Willem Groeneveld-Meijer
M.S. Mechanical Engineering, 2023
Does Finer Powder get deposited first in Powder Bed? A Comparative Study using Simulation and Experimental Techniques.
Ryan Stebbins
M.S. Mechanical Engineering, 2022
Novel Runner Extension Designs via 3D Sand-printing to Improve Casting Performance
Paula Clares
M.S. Additive Manufacturing & Design, 2022
Fundamental Understanding into Bimodal Powder Size Distributions in Binder Jetting Additive Manufacturing Process
Erik Jacobs
M.S. Additive Manufacturing & Design, 2021
Influence of Anti-Counterfeiting Taggants on the Tensile Properties of STEP Additively Manufactured Polymer
Nicholas Soares
M.S. Mechanical Engineering, 2021
Incorporating Novel Sprue Design and Additive Manufacturing Techniques to Improve Nickel Aluminum Bronze Castings
Daniel Martinez
M.S. Additive Manufacturing, 2019
Indirect Hybrid Manufacturing - Integrating 3D Sand-Printing for Metal Casting
Casey Bate
M.S. Mechanical Engineering, 2019
Fundamental Study on 3D Sand-Printed Molds: Metal Flow and Thermal Properties
Gregory Bicknell
M.S. Mechanical Engineering, 2019
Electrical Discharge Machining Process Design for Post-Processing Stainless Steel 316L Additively Manufactured Parts
Santosh Reddy Sama
M.S. Mechanical Engineering, 2018
Investigation into Non-Conventional Mold Design Using 3D Sand-Printing in Castings
Jiayi Wang
M.S. Engineering Design, 2017
Part Design and Topology Optimization for Rapid Sand and Investment Casting
Undergraduate
Joe Borst, Visiting student from Clarkson University
B.S. Mechanical Engineering, 2026
Joseph Daghir
B.S. Mechanical Engineering, 2025
Thomas Molnar
B.S. Mechanical Engineering, 2024
Avah Cherry, Visiting student from University of Tennessee
B.E. Aerospace Engineering, 2026
Rachel Bonfini
B.S. Biomedical and Mechanical Engineering, 2024
Valerie Fu
B.S. Mechanical Engineering, 2023
Christine Gabriele
B.S. Mechanical Engineering, 2023
Jay Sim
B.S. Mechanical Engineering, 2022
Shelby Bauer
B.S. Mechanical Engineering, 2022
Nick Vitagliano
B.S. Mechanical Engineering, 2021
Alex Cayley
B.S. Mechanical Engineering, 2021
Brianna Wilson
B.S. Industrial and Manufacturing Engineering, 2021
Israel Monroy
B.S. Mechanical Engineering, 2021
Hunter Snyder
B.S. Mechanical Engineering, 2019
Michael Szczesniak
B.S. Mechanical Engineering, 2018
James Lauer
B.S. Mechanical Engineering, 2018
News
What's happening at SHAPE.
$1.5M grant to develop advanced digital casting of manufacturing components
A Penn State team led by Guha Manogharan will use robot-assisted additive manufacturing to digitize casting through the Digi-FOCUS project.
$1.6M DARPA award for AM fatigue prediction
Dr. Manogharan was awarded $1.6 million through DARPA to improve prediction accuracy and reduce compute time for estimating service life of metal parts produced with additive manufacturing.
Kaitlyn Hartman awarded 2nd place in the MSEC 2025 student poster competition.
Recognized for work on functionally graded TPMS lattice structures for biomedical applications.
Joseph Daghir honored as a Spring 2025 Student Marshal.
SHAPE Lab undergraduate honors researcher Joseph Daghir was recognized for academic achievement and contributions to engineering student life.
Spring 2025
Congratulations to Ashish Jacob for being recognized with the 2025 Harold F. Martin Graduate Assistant Outstanding Teaching Award.
Current Events
Beyond welding: researchers 3D print two metals in a single complex structure.
Current Events
SHAPE Lab's multi-material laser powder bed fusion capabilities were featured by Additive Manufacturing Media.
Current Events
Dr. Guha Manogharan gave a Computational Design Symposium keynote on design optimization for multi-material laser powder bed fusion.
Current Events
Dr. Guha Manogharan was named co-director of Penn State's additive manufacturing center. Read more.
Current Events
Georgia Tech's Manufacturing Institute lecture series featured "Hybrid Additive Manufacturing: Role of AM in advancing traditional manufacturing methods" by Dr. Guha Manogharan.
Current Events
3D-Printing Grad Student Helps Optimize Emerging Technology by Paula Clares.
Current Events
3D-Printing Surgical Implants Inspires Engineering Graduate Student by Lauren Judkins.
Current Events
3D Printing for Better Flame From a Gas Turbine Swirler: The Cool Parts Show #42 from Additive Manufacturing Media.
Summer 2025
Congratulations to Kaitlyn Hartman for being awarded 2nd place in the MSEC 2025 student poster competition for her research poster titled "Functionally graded TPMS lattices structures for biomedical applications."
Spring 2025
SHAPE Lab undergraduate honors researcher Joseph Daghir has been honored as a Spring 2025 Student Marshal.
Spring 2025
Congratulations to Dr. Foxian Fan, who is starting as tenure-track assistant professor at Eastern Kentucky University.
July 2024
Congratulations to Dr. Ankit Saxena, who is starting as tenure-track assistant professor at the University of Wyoming.
July 2024
Congratulations to Dr. Sagar Jalui, who successfully defended his dissertation titled "AM-Driven Design Innovation: DfAM Constraints in Adjoint Shape Optimization for Gas Turbine Applications."
July 2024
Congratulations to Dr. Ankit Saxena, who successfully defended his dissertation titled "Systematic Design of Pressure-Actuated Adaptive Structural Cells Enabling Adaptive Mechanical Properties in Mechanical Structures."
May 2024
Congratulations to Jacklyn Griffis for being selected for the Naval Research Enterprise Internship Program 2024 at Naval Surface Warfare Center, Carderock Division.
August 2023
Congratulations to Carson Vath, who successfully defended his master's thesis titled "Development and Testing of Novel Multi-Material Additive Manufacturing Systems for Embedding Wire Electronics."
August 2023
Congratulations to Dr. Maryam Tilton, who is starting as tenure-track assistant professor at the University of Texas, Austin.
August 2023
Congratulations to Dr. Philip King, who is starting as tenure-track assistant professor at the University of Maine.
August 2023
Congratulations to Dr. Md Moinuddin Shuvo, who successfully defended his dissertation titled "Improving sustainability of Sand-Casting Processes via novel 3D Mold Designs."
August 2023
Congratulations to Dr. Foxian Fan, who successfully defended his dissertation titled "Evolution of Additive Manufacturing surface morphology during Centrifugal Disc Finishing."
August 2023
Congratulations to Dr. Philip King, who successfully defended his dissertation titled "Bridging the oldest and newest manufacturing technologies: Additive Manufacturing, Metal Casting, and Internet of Things."
August 2023
Congratulations to Sandy Karam, who successfully defended her master's paper titled "Additive Manufacturing of patient-specific high-fidelity and thickness-controlled cerebral aneurysm geometries."
August 2023
Congratulations to Willem Groeneveld-Meijer, who successfully defended his master's thesis titled "Does Finer Powder get deposited first in Powder Bed? - A Comparative Study using Simulation and Experimental Techniques."
August 2023
Congratulations to Jacklyn Griffis, who was awarded the Walker Graduate Assistantship with ARL.
May 2023
Congratulations to Foxian Fan, who was awarded the IISE Best Track Paper Award - Engineering Economy Division for "Cost Analysis of Mass Finishing Additively Manufactured Ti6Al4V Parts" at IISE 2023 in New Orleans, LA.
March 2023
Congratulations to Jacklyn Griffis for being selected for the Naval Research Enterprise Internship Program 2023.
January 2023
Congratulations to Ankit Saxena for being recognized with the 2022-23 Harold F. Martin Graduate Assistant Outstanding Teaching Award.
October 2022
Congratulations to Philip King for being awarded the Foundry Education Foundation scholarship for research in metal casting.
October 2022
Congratulations to Shuvo for being awarded the Foundry Education Foundation scholarship for research in metal casting.
October 2022
Congratulations to Shuvo for being awarded the Steel Founders Society of America award for research in metal casting.
June 2022
Congratulations to Philip King for being awarded NSF student support for the Solid Freeform Fabrication Symposium 2022.
June 2022
Congratulations to Shuvo for being awarded the Graduate Fellowship for research in metal casting.
May 2022
Congratulations to Ankit Saxena for being awarded the part-time graduate teaching excellence liaison by the Schreyer Institute for Teaching Excellence.
May 2022
Congratulations to Ankit Saxena for being awarded the 2022 ASME Graduate Teaching Fellowship.
May 2022
Congratulations to Paula Clares, who successfully defended her M.S. thesis in Additive Manufacturing & Design titled "Fundamental Understanding into Bimodal Powder Size Distributions in Binder Jetting Additive Manufacturing Process."
May 2022
Congratulations to Ryan Stebbins, who successfully defended his M.S. thesis in Mechanical Engineering titled "Novel Runner Extension Designs via 3D Sand-printing to Improve Casting Performance."
April 2022
Congratulations to Jay Sim for being awarded the Outstanding Undergraduate Research Achievement.
April 2022
Congratulations to Foxian Fan for the 2021-22 Harold F. Martin Graduate Assistant Outstanding Teaching Award.
April 2022
Congratulations to Paula Clares for the 2021-22 Distinguished Master's Thesis Award.
March 2022
Congratulations to Willem Groeneveld-Meijer for being awarded the Naval Research Enterprise Internship Program 2022.
August 2021
Congratulations to Jay Sim, who was awarded the Foundry Education Foundation scholarship for research in metal casting.
August 2021
Congratulations to Philip King, who was awarded the Foundry Education Foundation scholarship for research in metal casting.
June 2021
Congratulations to Sagar Jalui for being awarded NSF student support for the Solid Freeform Fabrication Symposium 2021.
June 2021
Congratulations to Ankit Saxena for being awarded NSF student support for the Solid Freeform Fabrication Symposium 2021.
June 2021
Congratulations to Nicholas Vitagliano for being awarded NSF student support for the Solid Freeform Fabrication Symposium 2021.
June 2021
Congratulations to Willem Groeneveld-Meijer for being awarded NSF student support for the Solid Freeform Fabrication Symposium 2021.
May 2021
Congratulations to Jay Sim, who was awarded the H. H. Harris Foundation scholarship for research in metal casting.
April 2021
Congratulations to Jay Sim for being awarded Second Best Presenter at the Undergraduate Research Exhibition.
August 2020
Congratulations to Philip King for winning the Penn State Energy and Environmental Sustainability Green Dollars Grant.
June 2020
Congratulations to Dr. Maryam Tilton on defending her dissertation titled "Multi-Objective Design and Characterization of Orthopaedic Implants and Meta-Biomaterials Fabricated via Additive Manufacturing."
May 2020
Congratulations to Dr. Xi Gong, who successfully defended his dissertation titled "Machining Behavior and Material Properties in Additive Manufacturing of TI-6AL-4V Parts."
May 2020
Congratulations to Jay Sim, who was awarded the H. H. Harris Foundation scholarship for research in metal casting.
April 2020
Congratulations to Jay Sim for being awarded Third Best Presenter at the Undergraduate Research Exhibition for work on Reinventing Foundry in a Box for the 21st Century.
March 2020
Congratulations to SHAPE Lab member Phil King, who was awarded the NSF Graduate Research Fellowship for work on numerical modeling and experimentation with novel 3D runner geometries.
March 2020
Congratulations to Jay Sim, who was selected for a 2020 PSU Erickson Discovery Grant for research in casting science.
January 2020
Congratulations to Jay Sim, who was awarded the Foundry Education Foundation scholarship for research in metal casting.
January 2020
Congratulations to Jay Sim, who was awarded the Spring 2020 Equity REU Grant to continue research redesigning AFS Foundry-in-a-Box.
December 2019
SHAPE Lab member Israel Monroy presented research work and findings at the Fall 2019 Design Showcase at University Park.
August 2019
Congratulations to Philip King, who was awarded the PA Manufacturing Fellowship for research in metal casting.
August 2019
Congratulations to Philip King, who was awarded the Foundry Education Foundation scholarship for research in metal casting.
August 2019
Congratulations to Jay Sim, who was awarded the Foundry Education Foundation scholarship for research in metal casting.
August 2019
Congratulations to Jay Sim, who was awarded the Fall 2019 Equity REU Grant to begin research on redesigning AFS Foundry-in-a-Box.
August 2019
Congratulations to Israel Monroy, who was awarded a scholarship from the College of Engineering for acceptance into the 2019 Fall REU program.
August 2019
SHAPE Lab member Daniel Martinez gave two technical presentations on "In-Direct Hybrid AM: Advancing Metal Castings via 3D Sand-Printing" and "Influence of 3D Sand-Printing Processing Conditions on Thermo-Mechanical Properties of Molds" at SFF 2019 in Austin, TX.
June 2019
SHAPE Lab member Daniel Martinez gave a poster presentation on "Improving mechanical properties of metal castings using novel sprue designs via 3D sand-printing" at ASME MSEC 2019 in Erie, PA.
April 2019
Congratulations to Maryam Tilton, who was awarded the DAAD RISE Professional 2019 Award and joined Zeiss 3D ManuFact in Germany for a three-month study and training program.
April 2019
Congratulations to Greg Bicknell, who successfully defended his M.S. thesis in Mechanical Engineering titled "Electrical Discharge Machining Process for Post-Processing Stainless Steel 316L Additively Manufactured Parts."
March 2019
Congratulations to Daniel Martinez, who was awarded the EESL Green Dollars grant for his project titled "Image Analysis of Pore Networks in 3D-Sand Printed Specimens Using Computer Tomography Scanning."
February 2019
Maryam Tilton presented work at the Orthopaedic Research Society Annual Meeting 2019 in Austin, TX on additively manufactured proximal humerus fracture fixation plates and patient-specific prostheses.
December 2018
Congratulations to Santosh Reddy Sama, who graduated with dual M.S. thesis degrees in Mechanical Engineering and Additive Manufacturing and Design.
December 2018
Congratulations to Santosh Reddy Sama, who published "Novel Sprue Design in Metal Casting via 3D Sand-Printing" in Additive Manufacturing.
August 2018
Congratulations to Santosh Reddy Sama, who published "Non-conventional mold design for metal casting using 3D sand-printing" in the Journal of Manufacturing Processes.
June 2018
SHAPE Lab member Santosh Reddy Sama gave a technical presentation on "Non-Conventional Mold Design for Metal Casting using 3D Sand-Printing" at NAMRC in College Station, TX.
May 2018
SHAPE Lab member Santosh Reddy Sama gave a technical presentation on "Topology Optimization for Metal Castings using 3D Sand-Printing including Manufacturing Constraints" at IISE 2018 in Orlando, FL.
May 2018
SHAPE Lab member Jiayi Wang gave a technical presentation on "Topology Optimization for Rapid Investment Casting of AM Patterns via Material Extrusion" at IISE 2018 in Orlando, FL.
April 2018
SHAPE Lab member Maryam Jahanzad gave a technical presentation on "How Can Additive Manufacturing Improve Fatigue Life in Fracture Fixations: An Experimental Study in Proximal Humerus Fractures" at RAPID 2018 in Fort Worth, TX.
April 2018
Congratulations to Jiayi Wang, who published "Re-Thinking Design Methodology for Castings: 3D Sand-Printing And Topology Optimization" in the International Journal of Metalcasting.
April 2018
Congratulations to undergraduate honors lab member Michael Szczesniak, who won the 2nd best presentation at the 2018 Undergraduate Research Exhibition for his thesis project, "Wire Arc Additive Manufacturing (WAAM) Utilizing a Low Cost, Closed Loop Current Control System."
December 2017
Jiayi Wang successfully defended his thesis on "Part Design and Topology Optimization for Rapid Sand and Investment Casting" and graduated with a master's in Engineering Design.
October 2017
An invited talk on "Advanced Hybrid Manufacturing: Roadmap of Technological Challenges" was presented at the 2017 Annual International Solid Freeform Fabrication Symposium.
October 2017
An invited talk on "Hybrid Manufacturing - Integrating Additive Manufacturing with Traditional Technologies" was presented at MetalStorm 2017.
May 2017
SHAPE Lab member Maryam Jahanzad gave a technical presentation on "Addressing Challenges in Custom Orthopedic Implants Using Additive Manufacturing" at RAPID 2017 in Pittsburgh, PA.
Sponsors
Sponsors and partners.
SHAPE Lab research is built around collaborations that connect manufacturing science to real application needs.
Government Partner
National Science Foundation
Industry Partner
America Makes
Government Partner
Air Force Research Laboratory
Government Partner
Office of Naval Research
Sponsor
Pennsylvania Manufacturing Sponsor
Government Partner
PA Department of Community and Economic Development
Government Partner
NIST Center of Excellence
Sponsor
Defense Manufacturing Sponsor
Industry Partner
IACMI - The Composites Institute
Industry Partner
Ascent FlexTech
Government Partner
DARPA
Partners
Publications
Manufacturing research outputs.
Papers from the official S.H.A.P.E. Lab publication list, grouped by research area and publication type.
Multi-Material Laser Powder Bed Fusion
-
Multi-material laser powder bed fusion: effects of build orientation on defects, material structure and mechanical properties
Griffis J.C., Shahed K., Meinert K., et al.
-
Multi-material additive manufacturing: a computational design perspective
Yu X., Griffis J., Manogharan G., Panesar A.
-
Multi-material additive manufacturing of metals: a review of structures and mechanical characteristics
Samad S.N., Griffis J., Manogharan G., Kouraytem N.
3D Sand-Printing & Metal Casting
-
Effect of novel riser design using 3D sand-printing on the defects and mechanical performance of a casting
Shuvo M.M., Skiadopoulos M., Shahed K.S., King P., Badamo T., Shokouhi P., Voigt R., Manogharan G.
-
Hands-on Digital Tools for Metalcasting Engineering Education in Foundry Science
King P., Sim J., Shahed K.S., et al.
-
Toward reducing casting defects via 3D risers via 3D sand-printing: a simulation study
Shuvo M., King P., Voigt R., Manogharan G.
-
Effect of freezing range on reducing casting defects through 3D sand-printed mold designs
Martinez D., King P., Sama S.R., et al.
-
Novel experimental method for metal flow analysis using open molds for sand casting
King P., Manogharan G.
-
A novel approach to visualize liquid aluminum flow to advance casting science
Bate C., King P., Sim J., Manogharan G.
-
Challenges and opportunities to integrate the oldest and newest manufacturing processes: metal casting and additive manufacturing
Lynch P., Hasbrouck C.R., Wilck J., Kay M., Manogharan G.
-
Towards functionally graded sand molds for metal casting: engineering thermo-mechanical properties using 3D sand printing
Martinez D., Bate C., Manogharan G.
-
Case studies on integrating 3D sand-printing technology into the production portfolio of a sand-casting foundry
Sama S., Badamo T., Manogharan G.
-
Measurement of metal velocity in sand casting during mold filling
Sama S., MacDonald E., Voigt R., Manogharan G.
-
Re-thinking design methodology for castings: 3D sand-printing and topology optimization
Wang J., Sama S., Manogharan G.
-
Design and topology optimization of 3D-printed wax patterns for rapid investment casting
Wang J., Sama S., Lynch P., Manogharan G.
-
Novel sprue designs in metal casting via 3D sand-printing
Sama S., Badamo T., Lynch P., Manogharan G.
-
Non-conventional mold design for metal casting using 3D sand-printing
Sama S., Wang J., Manogharan G.
-
Quantifying the role of part design complexity in using 3D sand printing for molds and cores
Almaghariz E., Conner B., Lenner L., Gullapalli R., Manogharan G., Lamoncha B., Fang M.
Orthopedic Applications of Additive Manufacturing
-
Automated segmentation of medical images for 3D printing - voxel-centric processing of spatially textured voxels
Cushing N., Fell B., Shahed K.S., Moser K.W., Manogharan G.
-
Fatigue properties of Ti-6Al-4V TPMS scaffolds fabricated via laser powder bed fusion
Tilton M., Borjali A., Griffis J., Varadarajan K., Manogharan G.
-
Biomechanical behavior of PMMA 3D printed biomimetic scaffolds: effects of physiologically relevant environment
Tilton M., Jacobs E., Overdorff R., Astudillo Potes M., Lu L., Manogharan G.
-
Current concepts in fracture healing: temporal dynamization and applications for additive manufacturing
Schmidt E.C., Judkins L.M., Manogharan G., Mehta S., Hast M.W.
-
Additively manufactured patient-specific prosthesis for tumor reconstruction: design, process, and properties
Tilton M., Lewis G.S., Hast M.W., Fox E., Manogharan G.
-
On structure and mechanics of biomimetic meta-biomaterials fabricated via metal additive manufacturing
Tilton M., Borjali A., Isaacson A., Varadarajan K.M., Manogharan G.P.
-
Finite element-predicted effects of screw configuration in proximal humerus fracture fixation
Tilton M., Armstrong A., Wee H., Hast M., Manogharan G., Lewis G.
-
Additive manufacturing of fracture fixation implants: design, material characterization, biomechanical modeling and experimentation
Tilton M., Lewis G., Wee H., Armstrong A., Hast M., Manogharan G.
-
Biomechanical testing of additive manufactured proximal humerus fracture fixation plates
Tilton M., Armstrong A., Sanville J., Chin M., Hast M., Lewis G., Manogharan G.
Hybrid Metal Additive Manufacturing
-
Hybrid additive manufacturing for Zn-Mg casting for biomedical application
Shahed K.S., Fainor M., Gullbrand S.E., et al.
-
Additive manufacturing: application and validation of machine learning-based process-structure-property linkages in Ti-6Al-4V
Gong X., Groeneveld-Meijer W., Manogharan G.
-
Additive manufacturing: a machine learning model of process-structure-property linkages for machining behavior of Ti-6Al-4V
Gong X., Zeng D., Groeneveld-Meijer W., Manogharan G.
-
Effect of prior surface textures on the resulting roughness and residual stress during bead-blasting of electron beam melted Ti-6Al-4V
Rifat M., Basu S., De Meter E.C., Manogharan G.
-
Rethinking reverse logistics: role of additive manufacturing technology in metal remanufacturing
Strong S., Kay M., Wakefield T., Sirichakwal I., Conner B., Manogharan G.
-
Hybrid manufacturing - locating AM hubs using a two-stage facility location approach
Strong D., Kay M., Conner B., Wakefield T., Manogharan G.
-
Adopting additive-hybrid manufacturing: the role of capacity in implementation decision
Strong D., Kay M., Wakefield T., Sirichakwal I., Conner B., Manogharan G.
-
Milling of Inconel 718 block supports fabricated using laser powder bed fusion
Tripathi V., Armstrong A., Gong X., Manogharan G., Simpson T., De Meter E.
-
Hybrid manufacturing - integrating traditional manufacturers with additive manufacturing (AM) supply chain
Strong D., Kay M., Conner B., Wakefield T., Manogharan G.
-
Longitudinal milling and fine abrasive finishing operations to improve surface integrity of metal AM components
Iquebal A., El Amri S., Shrestha S., Wang Z., Manogharan G., Bukkapatnam S.
-
Current state and potential of additive-hybrid manufacturing for metal parts
Strong D., Sirichakwal I., Manogharan G., Wakefield T.
-
Additive manufacturing-integrated hybrid manufacturing and subtractive processes: economic model and analysis
Manogharan G., Wysk R., Harrysson O.
-
AIMS - a metal additive-hybrid manufacturing system: system architecture and attributes
Manogharan G., Wysk R., Harrysson O., Aman R.
Additive Manufacturing Materials & Processing
-
Developing novel restrictive DfAM constraints for NURBS-based adjoint shape optimization for metal AM
Jalui S., O'Connor J., Xuan Y., Manogharan G.
-
Shape morphing metamaterials via pressure-actuated shape morphing cells
Saxena A., Rahn C., Manogharan G.
-
Mass finishing for additive manufacturing: tribological analysis, surface topology, image processing, predictive model, and processing recommendations
Fan F., Jalui S., Shahed K., Mullany B., Manogharan G.
-
Development of a method for shape optimization for a gas turbine fuel injector design using metal-additive manufacturing
Jalui S., Xuan Y., Manogharan G., O'Connor J.
-
Adaptive stiffness structures via additively manufactured fluid accumulators
Saxena A., Manogharan G., Rahn C.
-
Functionally graded TPMS gyroid structures for additive manufacturing of non-pneumatic tires
Shaikh A., Saxena A., Griffis J., Shahed K., Manogharan G.
-
Optimal design of AM support structures for EDM removal from build plate
Bicknell G., Shahed K.S., King P., et al.
-
Towards gradient design of TPMS lattices and laser powder bed fusion processing - role of laser strategies and lattice thickness
Shaikh A., Griffis J., Stebbins R., Shahed K.S., Saxena A., Ross A., Manogharan G.
-
Design-property decision-making in polymer lattices when controlling for printed mass
Clares P., Manogharan G., Thomas L., Krzeminski D.
-
Increasing density and mechanical performance of binder jetting processing through bimodal particle size distribution
Clares P., Gao Y., Stebbins R., van Duin A., Manogharan G.
-
Effects of part orientation, printer selection, and infill density on mechanical properties and production cost of 3D printed flexural specimens
Chen R., Baich L., Lauer J., Senesky D.G., Manogharan G.
-
A reactive molecular dynamics study of bi-modal particle size distribution in binder-jetting additive manufacturing using stainless-steel powders
Gao Y., Clares A.P., Manogharan G., van Duin A.C.T.
-
Dislocation microstructure and its influence on corrosion behavior in laser additively manufactured 316L stainless steel
Sprouster D.J., Cunningham W.S., Halada G.P., et al.
-
Molecular dynamics study of melting, diffusion, and sintering of cementite chromia core-shell particles
Gao Y., Clares Pastrana A.P., Manogharan G., van Duin A.C.T.
-
Mining design heuristics for additive manufacturing via eye-tracking methods and hidden Markov modeling
Mehta P., Malviya M., McComb C., Manogharan G., Berdanier C.G.
-
Mechanical behaviour and high strain rate deformation of stainless steel 316L processed by selective laser melting
Kneen T., Barrett C., Manogharan G., Carlson P., Dimon J., Conner B.
-
Influence of resin infiltrants on mechanical and thermal performance in plaster binder jetting additive manufacturing
Ayres T., Sama S., Joshi S., Manogharan G.
-
A ReaxFF molecular dynamics study of molecular-level interactions during binder jetting 3D-printing
Gao Y., Shin Y., Martinez D., Manogharan G., van Duin A.
-
Sliding contact wear damage of EBM built Ti6Al4V: influence of process induced anisotropic microstructure
Ryu J., Shrestha S., Manogharan G., Jung J.
-
Optimization of binder jetting using Taguchi method
Shrestha S., Manogharan G.
-
Experimental study of disruption of columnar grains during rapid solidification in additive manufacturing
Manogharan G., Yelamanchi B., Aman R., Mahbooba Z.
-
Microstructure and corrosion resistance of laser additively manufactured 316L stainless steel
Trelewicz J., Halada G., Donaldson O., Manogharan G.
-
Study of infill print design on production cost-time of 3D printed ABS parts
Baich L., Manogharan G., Marie H.
-
An assessment of implementation of entry-level 3D printers from the perspective of small businesses
Conner B., Manogharan G., Meyers K.
-
Binder jetting: a novel solid oxide fuel-cell fabrication process and evaluation
Manogharan G., Kioko M., Linkous C.
-
Making sense of 3-D printing: creating a map of additive manufacturing products and services
Conner B., Manogharan G., Martof A., Rodomsky L., Rodomsky C., Jordan D., Limperos J.
Book Chapters
-
Additive manufacturing of orthopedic implants
Tilton M., Lewis G.S., Manogharan G.P.
Peer-Reviewed Conference Proceedings
-
Continuous 5-axis routing of syringe deposited conductive traces over topology optimized structures
Williams M., Jacob A., Manogharan G.
-
Site-specific property informed interface design of multi-material laser powder bed fusion
Griffis J., Masker A., Schreiber J., Manogharan G.
-
Powder-binder interaction in binder jetting process: a simulation study on bimodal powders
Shahed K., Manogharan G.
-
Characterizing the training and evaluation of graduate teaching assistants (GTAs) at research-intensive universities
Saxena A., Hood L., Manogharan G., Berdanier C.
-
Development of a novel test artefact for conformal material extrusion printing
Jalui S.S., Zargar S.H., Moroney S., Putz M., Taylor M., Hatch S., Manogharan G.
-
Net-shape tensile specimens as representatives of material properties of metal additive manufacturing: evaluation and correction factor
Bass N., Jalui S., Manogharan G.
-
Investigation of wear behavior of centrifugal disc finishing on additively manufactured Ti6Al4V samples
Fan F., Jalui S., Lajoie N., Manogharan G.
-
Novel self-strengthening metamaterials via additive manufacturing
Saxena A., Manogharan G.
-
Strain-coupled fluidlastic circuits inside metal additive manufactured structures
Saxena A., Rai G., Lanari V., Rahn C.D., Manogharan G.
-
On additive manufacturing of rib fracture fixation implants: the role of lattice design
Judkins L., Gupta R., Gabriele C., Tomonto C., Hast M.W., Manogharan G.
-
A computational study on novel runner extension designs via 3D sand-printing to improve casting performance
Stebbins R., King P., Manogharan G.
-
Discrete-element simulation of powder spreading process in binder jetting, and the effects of powder size
Clares A.P., Manogharan G.
-
Novel riser designs via 3D sand printing to improve casting performance
Shuvo M.M., Manogharan G.
-
Abrasive flow machining of additively manufactured titanium: thin walls and internal channels
Jalui S.S., Spurgeon T.J., Jacobs E.R., Chatterjee A., Stecko T., Manogharan G.P.
-
Effects of centrifugal disc finishing for surface improvements in additively manufactured gears
Fan F., Soares N., Jalui S., Isaacson A., Savla A., Manogharan G., Simpson T.
-
Machining behavior and material properties in additive manufacturing Ti-6Al-4V parts
Gong X., Manogharan G.
-
Novel sprue designs to reduce casting defects in nickel-aluminum bronze: a computational study
King P., Martinez D., Manogharan G.P.
-
Effects of wire EDM parameters on traditionally and additively manufactured 316L stainless steel specimens
Bicknell G., Manogharan G.
-
3D printed sand molds - an opportunity for investment casters
Voigt R.C., Manogharan G.P.
-
Integrating metal AM with milling and non-traditional machining to enhance surface and tribological properties of AM parts
Iquebal A.S., Shrestha S., Wang W., Manogharan G.P., Bukkapatnam S.
-
Experimental investigation of nanoscale contact fatigue and surface wear damage of AM Ti6Al4V - Best Student Paper Award
Shrestha S., Manogharan G.P., Ryu J.
-
Impact of hybrid manufacturing on supply chain for metal parts
Strong D., Manogharan G.P., Sirichakwal I., Wakefield T.
-
Influence of milling and non-traditional machining on surface properties of Ti6Al4V EBM components
Iquebal A.S., Shrestha S., Wang Z., Manogharan G.P., Bukkapatnam S.
-
Influence of machining conditions in metal-hybrid additive manufacturing
Issacs A., Manogharan G.P., Wysk R., Harrysson O., Shrestha S., West H., Mahabooba Z.
-
Optimization of binder-jetting using Taguchi methods
Manogharan G.P., Shrestha S., Enriquez R.
-
Study of infill print parameters on mechanical strength and production cost-time of 3D printed ABS parts
Baich L., Manogharan G.
-
AIMS - a metal additive-hybrid manufacturing system: system architecture and attributes
Manogharan G., Wysk R., Harrysson O., Aman R.
-
Evaluating business strategies through mapping products fabricated by additive manufacturing
Conner P., Manogharan G.P., Martof A.N., Rodomsky L.M., Rodomsky C.M., Jordan D.C., Limperos J.W.
-
Hybrid manufacturing: unique approach to integrating additive and subtractive rapid prototyping process - Short-listed: Best Paper
Manogharan G.P., Wysk R.A., Harrysson O.L.A., Cohen P.H.
-
Load-monitoring systems in biomedical implants: a comprehensive review and proposed future directions
Manogharan G.P., Wysk R.A.
-
Failures in medical device development: an FDA perspective
Medina A., Manogharan G.P., Wysk R.A., Oudan-Kremer G.E.
-
Study of energy efficiencies in rapid prototyping
Manogharan G.P., Soundarajan D.K., Wysk R.A.
-
Effects of dynamic spindle speed on bone surface during machining
Manogharan G.P., Samayoa M.J., Harrysson O.L.A., Cohen P.H., Rivero I.V.
-
Overview of THR implants: design, failures, costs and future trends
Manogharan G.P., Medina L., Wysk R.A.
-
Economic model and analysis of cost effectiveness of rapid manufacturing
Manogharan G.P., Wysk R.A., Harrysson O.L.A.
-
The dynamic effects of pneumatic power instruments on machining of bone
Samayoa M.J., Manogharan G.P., Harrysson O.L.A., Cohen P.H., Rivero I.V.
-
Development of a CW NCRF photo-injector using solid freeform fabrication (SFF)
Frigola P., Harrysson O.L.A., Manogharan G.P., Medina F., et al.
-
Design of periodic cellular structures for heat exchanger applications
Kumar V., Manogharan G., Cormier D.R.
Conference Presentations
-
In-Direct Hybrid AM: Advancing Metal Casting via 3D Sand-Printing
Martinez D., Sama S.R., Toykoc H., Sim J., Manogharan G.
-
Influence of 3D Sand-Printing Processing Conditions on Thermo-Mechanical Properties of Molds
Martinez D., Bate C., Manogharan G.
-
High Strain Rate Mechanical Behavior of Stainless Steel 316L Processed by Selective Laser Melting
Kneen C., Barrett B., Conner, Manogharan G.P.
-
Wear and Corrosion Resistance of Metal AM Bio-Medical Parts
Shrestha, Manogharan G.P., Ryu J.
-
Sustainability in the Design and Fabrication of 3D-Printed Solid Oxide Fuel Cells
Manogharan G., Linkous C.A., Hammond J., Abraham M.A.
-
Sustainability in Engineering
Abraham A., Manogharan G.P.
-
A Structural, Surface Spectroscopic and Electrochemical Study of Printed Stainless Steel
Halada, Manogharan G.P., Cuiffo M.
-
Experimental Study of Disruption of Columnar Grain Growth during Rapid Solidification
Yelamanchi, Manogharan G.P., Cook J.
-
Influence of In-fill Print Parameters on Mechanical Strength and Production Cost-Time of 3D Printed ABS Parts
Baich, Manogharan G.P.
-
Mechanical Behavior at Various Strain Rates of Stainless Steel 316L Processed by Selective Laser Melting
Conner P., Kneen T.J., Manogharan G.P.
-
Experimental Disruption of Columnar Grain Growth during Rapid Solidification
Yelamanchi, Manogharan G.P.
-
Characterizing the high strain rate mechanical behavior of stainless steel 316L processed by selective laser melting
Kneen J., Bowers A.S., Conner B.P., Manogharan G.P.
-
Process mapping heated-bed 3D polymer printing
Manogharan G., Berfgors, Wysk R.A.
-
Challenges and Benefits of Hybrid Additive and Subtractive Manufacturing
Manogharan G., Harrysson O.L.A., Wysk R.A.
-
Load-monitoring Systems in Biomedical implants: A comprehensive review and proposed future directions
Manogharan G., Wysk R.A.
-
Study of Effects on Production Economics using 3D Printed Sand Casting Molds
Limperos, Jordan D., Manna M., Pflager D., Manogharan G.P.
-
Hybrid Manufacturing - Integrating Additive and Subtractive Methods
Manogharan, Harrysson O.L.A., Wysk R.A.
Gallery
Snapshots from SHAPE Lab.
Photos from lab events, student milestones, and research moments.
.jpg)
Contact
Connect with S.H.A.P.E. Lab.
Build the next manufacturing system with SHAPE Lab.
The lab works across additive manufacturing, hybrid process engineering, 3D sand printing, biomedical AM, and multi-material metal systems.
- Location: Penn State, Department of Mechanical Engineering
- Office: 330 Leonhard Building
- Phone: 814 863 7273
- Email: gum53@psu.edu
Where the world tunes in from.
A privacy-preserving snapshot of visitor locations. GitHub Pages displays fallback totals unless an external analytics feed is connected.
Total visits
0
Countries
0
Cities
0
GitHub Pages can show this map, but live location totals need a separate analytics endpoint.
Top countries
- Awaiting analytics
Top cities
- Awaiting analytics