NAMRC 53 | MSEC 2025

NAMRC 53/MSEC 2025 Workshops

Workshop intent and format

The intent is to provide an introduction and overview of topics related to NAMRC/MSEC attendees. The target audience is attendees with topic interest, but not deep experience. The workshop should provide both fundamentals and applications. The workshop length will be approximately two hours, and the format will be lecture-style and hands-on workshops. See individual workshop descriptions for further details.

All the workshops will be conducted on Monday, June 23, 2025.

For any workshops held at the offsite location (CUICAR), attendees are responsible for arranging their own transportation. 

CUICAR Address: 4 Research Drive, Greenville, SC, USA 29607 

Workshop descriptions

Testbed as a Service: Getting Started with Streaming Authentic Manufacturing Datasets 

Workshop Organizers: 

R. McCormick, PhD Candidate in Mechanical Engineering, Molinaroli College of Engineering and Computing & McNair Aerospace Center, University of South Carolina

Fadi El Kalach, PhD Candidate in Automotive Engineering, Clemson Composites Center, Clemson University. 

Thorsten Wuest, Professor of Mechanical Engineering, Molinaroli College of Engineering and Computing & McNair Aerospace Center, University of South Carolina 

Workshop Description:

Smart and Advanced Manufacturing applications require data to generate actionable insights. However, commissioned testbeds in academia and data from production systems in industry are scarce, and when they are available, the acquisition of authentic data from commissioned testbeds is fraught with challenges. 

To improve access to commissioned testbeds which provide authentic streaming data for both remote solution development and the edge deployment of developed solutions, the (Testbed as a Service (TaaS) method), (tooling), and (dataset 1 and dataset 2) enable researchers, educators, and students to gain access to manufacturing testbeds and stream data derived from them, as well as test developed solutions to manufacturing problems.  

This material is based upon work supported by the National Science Foundation under Grant No. 2119654. Any opinions, findings, conclusions, or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the National Science Foundation. 

Main Takeaways 

This workshop will provide an overview and introduction to the method, tooling, and datasets to  

1) Enable workshop participants to utilize provided tooling and datasets to support their research and education objectives. 

2) Provide a foundation for the owners of commissioned testbeds to publish streaming data for researchers, educators, and students to consume.  

3) Workshop participants will get hands-on with TaaS tooling and data streaming from two manufacturing testbeds:  

• Cell phone assembly line 

• Rocket assembly line. 

 Relevance of Workshop Topic 

This tutorial aligns with the objectives of disseminating tools and software that will facilitate the adoption of Smart Manufacturing and Industry 4.0 techniques in both academia and industry. Attendees will gain valuable knowledge in utilizing new technologies that accelerate the development of intelligent solutions on the factory floor across disciplines and backgrounds. This ensures the tutorial is highly valuable for participants looking for theoretical and practical advancements and their translation into meaningful real-world applications. 

Participant Prerequisites: 

• Attendees must bring a computer that meets the following requirements: 

• Must be amd64/x86-64 architecture (Mac M1-M3, Raspberry Pi, and arm64/aarch64 will not work) 

• ≥ 2 CPU Cores Required, ≥ 4 CPU Cores Recommended 

• ≥ 12 GB RAM Required, ≥ 16 GB RAM Recommended, must be able to allocate 8 GB of RAM to a Virtual Machine 

• 60 GB Free Disk Space for a Virtual Machine 

• Oracle Virtualbox Installed 

• An operating system that natively support extracting .7z archives, or 7zip installed: operating system download 

• Knowledge of the following technologies and software are recommended but not required: 

• Virtualization, Oracle Virtualbox 

• Containerization, Docker 

• Distributed Version Control, Git 

 Agenda: 

• Introduction to Testbed as a Service Method (30 minutes) 

• Configure Virtual Machine (15 minutes) 

• Hands-On Session: Guided Tour of Datasets and Tooling (45 minutes) 

• Creating and Deploying Modules (15 minutes) 

• Q&A and Open Discussion (15 minutes) 

Presenter Bios 

R. McCormick is a multi-disciplinary engineer with more than 15 years of industry experience spanning product, process, machine, and tooling design, including R&D across the steel, glass, stamping, wire mesh, HVAC, and plumbing industries. He has received the NAMRI SME Outstanding Reviewer Award and has been funded by NSF, DoE, DoD, and Penn State.

Fadi El Kalach is a PhD Candidate in Automotive Engineering at the Clemson Composites Center. His research focuses on explainable data-driven intelligent manufacturing using time-series analytics and semantic web technologies, is funded by NSF and SCRA, and has collaborated with Siemens and IBM, publishing in venues such as JMS, JIM, and RCIM. 

Dr. Thorsten Wuest is a Full Professor of Mechanical Engineering at the University of South Carolina and is globally recognized as one of SME’s 20 most influential professors in smart manufacturing. He has co-authored 3 books and more than 170 refereed journal and conference articles, gathering over 12,600 citations to date. His research is funded by NSF, NIST, DoD, DoE, EPA, TJF and others. He serves as Vice-Chair Americas for IFIP WG5.7, AE for RCIM, SSMS, and IJMR, on EB for JMSY and PMR, and on advisory boards of the Knudsen Institute, Maven Machines and Sustainment. 

Metal Additive Manufacturing 

Organizer: 

Shunyu Liu, Automotive Engineering, Clemson University 

Workshop Description: 

This workshop aims to equip participants with fundamental knowledge and practical skills in metal additive manufacturing, with a focus on fabricating high-performance structures and synthesizing multifunctional materials for critical applications. It will begin with an introduction to key wire- and powder-based metal additive manufacturing technologies, highlighting different joining methods that create metallurgical, physical, and mechanical bonds in the fabricated parts. Industry case studies will be presented to showcase real-world applications. Attendees will also have the opportunity to visit the Additive Manufacturing and Advanced Materials (AM&AM) Laboratory at Clemson University, explore the metal printers, and examine demonstration samples. Additionally, a live demonstration of printers in operation will be provided. 

Agenda: 

• Overview of metal additive manufacturing technologies (20 mins) 

• Industry case studies and applications (20 mins) 

• Tour of the AM&AM Laboratory (30 mins) 

• Examination of demonstration samples (20 mins) 

• Live printing demonstration (20 mins) 

• Q&A and Open Discussion (10 mins) 

Instructor’s short bio: 

Shunyu Liu joined the Department of Automotive Engineering at Clemson University as an Assistant Professor in January 2021 after earning her Ph.D. in Mechanical Engineering from Purdue University in December 2020. Her research areas include laser additive manufacturing (AM), hybrid AM, advanced materials development, computational materials science, and machine learning. Her experimental research focuses on structural and functional metals, multi-material fabrication, and advanced materials for extreme environments. Her computational research centers on developing simulation frameworks to model process-microstructure-property relationships for laser AM. She is also building a thermal-mechanical-metallurgical model for a novel hybrid in-situ rolled AM process. Additionally, she integrates machine learning for materials design, process optimization, and defect control. She is the recipient of the NSF CAREER Award (2023), the SME Susan Smyth Outstanding Young Manufacturing Engineer Award (2024), and the NSF EPSCoR Research Fellowship (2025). Over the past four years at Clemson, she has secured nine grants totaling ~$10 million, with over $2.6 million as her share, funded by NSF, DOE, ARL, and Clemson University. With expertise in advanced manufacturing, materials science, solid mechanics, and applied mathematics, her research aims to pioneer cutting-edge manufacturing techniques and develop innovative materials for next-generation applications.  

Control of Manufacturing Systems, Machines, and Processes in the Context of Industry 4.0 

Organizers: 

Chinedum (“Chi”) Okwudire, University of Michigan 

Workshop Description: 

The control of manufacturing systems, machines and processes is being transformed by the technologies shaping the smart manufacturing (Industry 4.0) revolution. This tutorial will briefly review some key technologies, like the Internet of Things (IoT), cloud computing, artificial intelligence/machine learning, and digital twins, that are driving smart manufacturing. Then it will provide industrial case studies and specific examples of how participants can leverage these technologies to improve the quality, productivity and/or cost-effectiveness of manufacturing machines and processes through advanced control. The tutorial will be very interactive and will not assume any prior background in control theory. 

At the end of this tutorial, participants will be able to: 

1. Appreciate key technologies shaping Smart Manufacturing, and their relevance to manufacturing control 
2. Identify major classes of control used in manufacturing and other industries and their importance  
3. Identify some industry-relevant cases where advanced control, supported by smart manufacturing technologies, is leading to large improvements in performance 

Tentative Agenda (Subject to Change) 

• Introduction (10 min) 

• Overview of Relevant Smart Manufacturing Technologies (30 min) 

• Stretch Break (5 min) 

• Overview of Basic and Advanced Control Methods (40 min) 

• Stretch Break (5 min) 
• Examples of Controls in the Context of Industry 4.0 (30 min)

Organizers Bio:

Chinedum (Chi) Okwudire is a Professor of Mechanical Engineering and Miller Faculty Scholar at the University of Michigan. His research is focused on exploiting knowledge at the intersection of machine design, control and computing to boost the performance of manufacturing automation systems at low cost. Chi has received a number of awards, including the CAREER Award from the National Science Foundation; the Young Investigator Award from the International Symposium on Flexible Automation; the Outstanding Young Manufacturing Engineer Award from SME; the Ralph Teetor Educational Award from SAE International; the Education Award from SME; and the Russell Severance Springer Visiting Professorship from UC Berkeley. In 2022, he was selected by SME as one of the 25 leaders transforming manufacturing. He has co-authored several award-winning papers in the areas of manufacturing automation, control and mechatronics. He is the founder and CTO of Ulendo Technologies Inc., a company focused on advanced automation solutions for the manufacturing industry. 

New Hybrid Molding Technologies for Composites and Multi-Materials Parts 

Organizers: 

Saeed Farahani, Clemson Composites Center, Clemson University 

Ramy Harik, Clemson Composites Center, Clemson University 

Workshop Description: 

This workshop introduces several new innovative hybrid molding techniques that have recently been developed based on different integrations of injection-based processes with forming, foaming and additive manufacturing technologies with the aim of cost-efficiently manufacturing composites and multi-material parts and/or increasing the performance and functionality of such parts. The session will cover both theoretical and practical aspects of these technologies. As part of this workshop, participants will get the chance to visit Clemson Composites Center (CCC) and its unique large-scale hybrid manufacturing cell. This workshop will end by engaging attendees in a hands-on activity that allows participants to design and produce a personalized souvenir using a hybrid process known as Additive Insert Molding (AIM). 

Agenda: 

• Introduction to several hybrid molding technologies (20 mins) 

• Tooling, modeling, and process control challenges (20 mins) 

• Visit and demonstration of CCC’s large-scale hybrid manufacturing cell (20 mins) 

• Hands-on Session (50 mins): 

• Introduction to the equipment and safety procedures. 

• Attendees will design and 3D print inserts using pre-configured templates. 

• Demonstration of the AIM process to make custom items. 

• Open discussion for questions and future applications (10 mins) 

Instructor’s short bio: 

Saeed Farahani is an Assistant Professor in the School of Mechanical and Automotive Engineering and the Associate Director of Clemson Composites Center. He has B.S. and M.S. degrees in Mechanical Engineering from Sharif University and Ph.D. in Automotive Engineering (manufacturing field) from Clemson University. His research is primarily in the field of advanced manufacturing, particularly in the areas of hybrid and smart manufacturing systems. His research has integrated analytical models, numerical simulations, statistical and machine learning methods, sensors, and industrial IoT solutions to advance manufacturing systems for composites and multi-material/functional components. His research has been sponsored by DOE, DOD, DOC, SCRA, and multiple companies. Farahani has also more than 10 years of working in the industry in the field of design and manufacturing special tools and machinery. He serves as an associate editor for the SAE Journal of Sustainable Transportation, Energy, Environment, & Policy (STEEP), the chair of the Advanced Materials Manufacturing Technical Committee in the ASME Manufacturing Engineering Division, and a board member of the Injection Molding Division in the Society of Plastic Engineering. 

Ramy Harik, a Fulbright Alumni, is the Director of the Clemson Composites Center and a Professor of Automotive Engineering at Clemson University. Ramy holds degrees in Mechanical Engineering (B.S./M.S.), Automated Manufacturing (M.S.), and Industrial/Mechanical Engineering (Ph.D.). His teaching focuses on Manufacturing, Smart Manufacturing, and Composites Manufacturing. Harik serves as an Associate Editor for SME Manufacturing Letters and authored the “Introduction to Advanced Manufacturing” textbook published by SAE. He has secured over 15 million USD in funding from NASA, Boeing, and others. Recognized as one of the top 20 influential professors in Smart Manufacturing by SME’s Smart Manufacturing Magazine in 2020, he has extensive teaching experience globally and has supervised over 30 graduate students and founded research initiatives. 

Solid-State Metal Additive Manufacturing (SSAM) 

 Organizers: 

Frank Pfefferkorn, University of Wisconsin-Madison 

Workshop Description: 

This tutorial describes the deposition (printing) of metal using processes in which the material does not exceed the melting point. This is achieved by hot-working the metal: temperatures are usually between 70%  and 95% of the solidus temperature. Metal is deformed and bonded to the substrate by utilizing friction, pressure, velocity, and time. The severe plastic deformation during deposition results in a fine-grained microstructure. The dynamic recrystallization and lower temperatures and temperature gradients, compared with melting-based processes, result in less formation of intermetallic phases, oxides, and residual stresses. It must also be noted that the hot working nature of the processes results in large forces and torques (at least locally). Significant advantages of these processes are their ability to deposit almost any metal alloy, create deposits/bonds between dissimilar materials, and achieve high deposition rates. However, significant knowledge gaps still exist in how to achieve the full potential of SSAM. The solid-state additive manufacturing processes are still in the early stages of adoption, and this tutorial aims to provide a foundation of information that will enable the attendee to begin the process of evaluating these processes for their application(s) and pursue additional sources to increase their knowledge. 

Agenda: 

• Speaker introduction 

• Overview of metal additive manufacturing (AM) 

• Overview of solid-state additive manufacturing (SSAM) 

• Introduction of SSAM 

• Sintering-based processes 

• Electro-chemical-based processes 

• Friction-based processes 

• Overview of Process Physics  

• Friction Surfacing 

• Additive Friction Stir Deposition 

• Research Insights 

• Microstructures 

• Bond formation 

• Process window 

• Process control 

• Feedstock (solid, loose) 

• Oxidation 

• Residual stresses 

• Multi-material 

• Energy consumption 

• Applications 

• Repair 

• Industrial symbiosis/point of interest recycling/upcycling 

• Large-scale structures 

• Comparison of hybrid Friction Surfacing (rod) to Wire Arc Additive Manufacturing and Directed Energy Deposition (powder)  

• Summary of benefits, challenges/limitations, and future directions  

Instructors Short Bio:

Dr. Frank Pfefferkorn is a Professor and the Associate Chair for Graduate Studies in the Department of Mechanical Engineering and the Director of the Manufacturing Systems Engineering Program at the University of Wisconsin-Madison. His Doctoral Degree is in Mechanical Engineering from Purdue University in West Lafayette, IN (2002). His core expertise is in the experimental and numerical investigation of discrete metal part manufacturing process physics. Dr. Pfefferkorn's research focuses on where the tool meets the workpiece, whether that tool is a mechanical cutting tool, laser beam, or friction stir tool. He has conducted advanced manufacturing process research for 29 years. He has active research projects in solid-state joining, laser polishing, instrumenting cutting tools, solid-state metal additive manufacturing, and multi-material additive subtractive manufacturing. Dr. Pfefferkorn has authored over 165 peer-reviewed publications in these areas, including journal articles, conference proceedings, and invited book chapters. His research has been funded by the US National Science Foundation, US Department of Energy, US Office of Naval Research, Wisconsin Alumni Research Foundation, Machine Tool Technology Research Foundation, Austrian Marshall Plan Foundation, and industry. 

Clemson’s Deep Orange Student-Led Vehicle Development Process 

Organizers: 

James Forbes, Automotive Engineering, Clemson University  

Workshop Description: 

This workshop offers an in-depth look at the vehicle development process undertaken by our graduate students as they pursue their M.S. degrees in Automotive Engineering through the Deep Orange program. This unique program combines both theoretical knowledge and hands-on experience, providing students with the skills needed to design and build one of the most intricate consumer products- the automobile. Participants will gain insight into the broad scope of automotive engineering, exploring key aspects such as design, prototyping, and testing. We will also delve into the history of the Deep Orange program, highlighting its evolution and impact on industry. Additionally, we will outline the structured development process that guides students from the initial concept to a fully functional vehicle. As part of the workshop, attendees will have the opportunity to tour our state-of-the-art labs, where much of this innovative work takes place. The session will conclude with an up-close look at several past vehicles developed through the program, offering a tangible representation of the creativity, engineering, and dedication that define Deep Orange. 

Agenda: 

• Scope of Automotive Engineering (20 min) 

• History of Deep Orange (20 min) 

• Lab Tours (20 min) 

• Discussion of the overall development process (50 min) 

• Target customer definition 

• Requirement Development 

• Initial Digital Design 

• Analytical Development 

• Fabrication 

• Testing 

• Roll out / Unveiling 

• Questions (10 min) 

Instructor’s short bio: 

James Forbes is a professor of Practice in Automotive Engineering at the Clemson University-International Center for Automotive Research (CU-ICAR). He received his B.S. and M.S. degrees in Mechanical Engineering from Worcester Polytechnic Institute in Massachusetts. He then went on to work for Ford Motor Company for over 32 years in a wide range of vehicle engineering roles. His career has focused on the many aspects of vehicle systems and attribute engineering, working in a structured systems-engineering approach with global engineering teams.