At Southern Illinois University Carbondale, Professor Sangjin Jung is leading a research project focused on improving the reliability of 3D-printed metal components. Supported by a $200,000 grant from the National Science Foundation, his team is exploring how additive manufacturing processes can be designed so that parts maintain their structural integrity even in the presence of unavoidable microdefects. The goal is to facilitate the industrial adoption of additive manufacturing and strengthen confidence in metal-based 3D printing technologies.
Tiny defects such as pores or cracks often occur due to fluctuations in laser power, scan speed, or powder quality. These irregularities can compromise the strength and lifespan of parts.
“Real production isn’t perfect,” Jung said. “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,” Jung said, noting that the grant can help position SIU and regional businesses as a hub for additive manufacturing.
His team’s approach is based on simulation-driven models that quantify the likelihood and impact of such defects. The geometry and structure are then intentionally adjusted to ensure the parts remain tolerant to these weaknesses.
“In all these cases,” Jung said, “the ability to create tailored, intricate geometries gives AM a clear advantage over traditional methods.”
Jung brings both industrial and academic experience to the project. Before joining the university, he worked as a research engineer at LG Electronics and as a scientist at Carnegie Mellon University and Pennsylvania State University. The research also aims to enhance university teaching: students from mechanical and materials engineering are collaborating on interdisciplinary projects that combine simulation, optimization, and practical printing.
“The research simulates how real-world defects affect performance and then refines the design accordingly,” Jung said. “This will dramatically cut costly experimental iterations while producing designs that align with real manufacturing conditions.”
In the long term, this approach could make additive manufacturing more attractive for mass production. If it can be shown that robust designs compensate for process variations, quality assurance could be simplified, expanding the use of metal 3D printing in safety-critical industries such as aerospace and medical technology. Jung sees this as an important step toward establishing additive manufacturing as a reliable production technology.
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