Invisible Signatures: AI Pinpoints the Printer Behind 3D-Printed Parts
A team led by Professor Bill King in the Grainger College of Engineering at the University of Illinois Urbana-Champaign has revealed that every 3D-printed part carries a machine-specific “fingerprint” in its surface texture—and they’ve built an AI system that can identify the exact printer from a simple photograph. By training a deep-learning model on over 9,000 parts produced by 21 industrial machines across four additive-manufacturing processes, the researchers demonstrated 98 percent accuracy in tracing parts back to their source with just one square millimeter of imagery. This breakthrough promises to transform supply-chain oversight—automatically verifying that suppliers use approved equipment, processes, and materials—and to detect unauthorized changes or defects early in the production process. Beyond industrial quality control, King envisions the technology helping law enforcement track the origin of illicitly manufactured goods, offering unprecedented transparency in a world of tens of millions of 3D-printed components. Discussions are available here, here, here and here.
Unveiling AI “Fingerprinting” to Track 3D-Printed Parts Back to Their Printers
Professor King’s research lab has developed a groundbreaking AI system that identifies the precise 3D printer used to fabricate an additively manufactured component by detecting a unique “fingerprint” each machine leaves on part surfaces. Trained on 9,192 parts produced on 21 printers from six manufacturers using four distinct processes, the deep-learning model can analyze a single square millimeter of a smartphone photograph to pinpoint its origin with 98 percent accuracy—and it needs as few as ten exemplar parts to audit every subsequent batch reliably. “Even when two identical printers run the same design, settings, and material, each leaves a signature we can trace back,” King says, noting that this capability could replace traditional, trust-based supplier audits by spotting unauthorized changes in machines or materials early and preventing costly defects. Published in npj Advanced Manufacturing, the work promises tighter supplier oversight and quality control and broader applications, such as tracing illicit or counterfeit parts, while paving the way for seamless integration into digital supply-chain platforms and inspection workflows. Discussion is available here.
Illinois Grainger Engineering Launches DoD-Funded Center for Large-Scale Metal Additive Manufacturing
Under the leadership of Professor Bill King, the Grainger College of Engineering at the University of Illinois Urbana-Champaign has secured an $8.15 million award from the U.S. Department of Defense to establish the world’s first university research center dedicated to large-metal additive manufacturing. In partnership with the Army’s DEVCOM Ground Vehicle Systems Center and the Rock Island Arsenal Joint Manufacturing and Technology Center, the center will mount two large-format printers in a factory demonstration facility at the University Research Park, where faculty and students will answer fundamental questions about material properties, part quality and process scale-up for components three feet and larger. By focusing on emerging techniques such as friction stir welding AM and integrating advanced sensing, materials characterization, and design tools, the initiative aims to transform military ground vehicle supply chains, bolster regional economic growth in the Quad Cities, and strengthen U.S. manufacturing resilience. Discussions are available here, here, and here.
Additively Manufactured Heat Exchanger Beats out Traditional Designs
A groundbreaking project led by Professors Bill King and Nenad Miljkovic at the University of Illinois is revolutionizing the design and manufacturing of heat exchangers through additive manufacturing, or 3D printing. Traditionally, the design and manufacturing of heat exchangers have remained unchanged for decades due to manufacturing limitations. However, this innovative approach allows for complex 3D geometries that significantly improve heat transfer efficiency. Working with the U.S. Navy, the team developed a two-phase heat exchanger that surpasses traditional designs by 30% to 50% in performance. This advancement enhances energy efficiency and facilitates the integration of high-power devices in mobile applications like cars, ships, and aircraft. With modeling and simulation tools, the team explored thousands of design possibilities, collaborating with companies focused on energy efficiency to push the boundaries of current technology even further. Discussion is available here.
Grainger Engineers Are Bringing Manufacturing Into The Future
The Grainger College of Engineering at Illinois has launched the Illinois Manufacturing Institute (IMI) to elevate advanced manufacturing processes, led by Professor Bill King. This initiative aims to integrate cutting-edge technologies like artificial intelligence, IoT, and additive manufacturing into manufacturing processes. The IMI will bring together research efforts under one umbrella, including notable projects on autonomous construction, network communication infrastructure, energy-efficient materials, and cryogenic engineering. In the Quad Cities region, King is driving collaborations with the U.S. Army Arsenal at Rock Island to enhance additive manufacturing technologies. Grainger faculty members, such as Marie Charpagne, Iwona Jasiuk, and Kathryn Matlack, are pioneering research in areas like metal alloys suited for 3D printing, lightweight lattice structures, and noninvasive material characterization using ultrasonic waves. Their work supports sustainable manufacturing and aims to have direct impacts on various industrial applications, from nuclear energy to automotive and defense sectors. Discussion is available here.
Engineering Takes on Cancer
The Illinois Grainger Engineering College is advancing cancer research with two significant ARPA-H grants totaling $54 million, underscoring the role of engineering in innovative cancer solutions. One project, led by Bill King, focuses on using digital manufacturing to create reproducible 3D tumor models for personalized medicine. The second project, headed by Stephen Boppart, aims to develop an AI-powered imaging system for real-time detection of cancerous tissue during surgery, thereby minimizing reoperations. These initiatives reflect the integration of engineering principles in tackling complex biomedical challenges and highlight collaborative efforts across various university departments and clinical partners. Discussion is available here.
Medicine and Engineering Unite at The University of Illinois Cancer Research
The University of Illinois Urbana-Champaign is advancing cancer research by merging medicine and engineering expertise. Professors Dr. King and Stephen Boppart discussed their initiatives on Community Voices, focusing on producing uniform 3D tumor models for research testing and developing enhanced optical imaging technologies. These innovations aim to improve surgical precision in cancer cell removal, potentially transforming cancer treatment and research approaches. Discussion available here.
Building A Better Cancer Tumor
Scientists clone cancer cells from patient biopsies in 2D cultures on flat surfaces, unlike 3D tumors in humans, and although 3D tumor models exist, they lack consistency across labs, limiting cancer research. Dr. King leads a project funded by the Advanced Research Projects Agency for Health to improve the creation of 3D tumors using robotics and advanced imaging. This initiative, starting with a common type of breast cancer, seeks to develop a scalable digital manufacturing platform that can eventually be used for various cancers, including rare and understudied types, overcoming current limitations in cancer research automation and scalability. Press is available here.
ARPA-H Project to Pioneer Rapid Manufacturing of Tumor Models
Dr. King is spearheading a $21 million project funded by the Advanced Research Projects Agency for Health (ARPA-H) to develop a novel platform for manufacturing 3D tumor models. These advanced models, superior to traditional two-dimensional cultures, will use artificial intelligence, robotics, and vision systems to replicate cancer behaviors more accurately. The project, which includes co-PI Rohit Bhargava and support from the Grainger College of Engineering, aims to enhance the accessibility of 3D tumor models for personalized medicine and medical research, potentially revolutionizing cancer treatment and research methodologies. Press is available here.
Quad Cities Manufacturing Institute to Serve Defense, Other Sectors
The Quad Cities Manufacturing Institute (QCMI) has been launched to drive advancements in the defense and manufacturing sectors across the Midwest, through a partnership involving Western Illinois University, the University of Illinois System, and Iowa State University. Spearheading research and workforce development in advanced manufacturing and materials, QCMI aims to foster collaboration with the U.S. Army Rock Island Arsenal and regional businesses. Researchers, including Dr. King, are involved in developing new materials to enhance military protection, underscoring QCMI’s role in promoting innovation and economic growth in the region. Press available here.
King Begins Term on ASME Board of Governors
Dr. King has been elected to the American Society of Mechanical Engineers (ASME) Board of Governors for the FY 2024-27 term. As part of the board, King will help guide ASME’s strategic plans through various committees. A distinguished member and ASME Fellow since 2011, King’s accolades include the Bergles-Rohsenow Young Investigator Award, Gustus-Larson Memorial Award, and the 2023 William T. Ennor Manufacturing Technology Award, highlighting his significant contributions to the field. Press is available here.
King Receives The Highest Campus Honor for Faculty Mentoring
Dr. King was recently honored with the 2024 Campus Award for Excellence in Faculty Mentoring, recognizing his exceptional commitment to the professional and personal development of his mentees. Nominated by Professor Sameh Tawfick and supported by numerous colleagues, King was acknowledged for his personalized guidance, career advice, and empathetic support. He was celebrated at the university’s Celebration of Academic Service and Leadership Excellence on May 14. Press is available here.
King Wins Top ASME Award for Manufacturing Achievements
Dr. King has been awarded the 2023 ASME William T. Ennor Manufacturing Technology Award, the highest honor for manufacturing-related engineering. King was recognized for his significant contributions to innovative manufacturing technologies, particularly his leadership at the Digital Manufacturing and Design Innovation Institute (DMDII) and his role as co-founder and Chief Scientist at Fast Radius Inc., where his work has influenced the manufacturing sector globally. His research has led to 20 U.S. patents and advancements in digital manufacturing, nanometer-scale measurement, and high-resolution dimensional metrology. Press is available here.
Five Grainger Engineers Are Investigators in The 2024 MURIs, Including One Principal Investigator
Grainger Engineering at the University of Illinois Urbana-Champaign is participating in four 2024 Multi-University Research Initiatives (MURIs) funded by the U.S. Department of Defense. These initiatives support interdisciplinary research teams across multiple institutions. Among the Illinois researchers, professors Bill King and Nenad Miljkovic will apply machine learning to improve phase change heat transfer systems. Each project is awarded $1.5 million annually for three years, with potential for extension, underlining the competitive and impactful nature of these research endeavors. Press is available here.
The Grainger College of Engineering and Carle Health Demonstrate A Working Prototype of Emergency Ventilator for COVID-19 Patients
A team led by Dr. King has produced a prototype emergency ventilator to help address the expected surge in the need for respiratory care associated with the COVID-19 pandemic. The Illinois RapidVent, as the emergency ventilator is known, would plug into the oxygen source available in most hospital rooms or could plug into a tank of oxygen. The prototype has run for more than 75 hours, which is more than 125,000 breathing cycles. Over this time, the device delivered the amount of oxygen necessary and the pressure that patients would need when they are unable to breathe well enough on their own. So far, focused testing in the laboratory shows equivalent performance to commercial products, which are in very short supply. Press is available here.
MechSE Researchers Demonstrate New Capability for Electronics Cooling Using Additive Manufacturing
Researchers in Dr. King’s group have demonstrated a new type of air jet cooler that overcomes previous barriers to jet cooling systems. Using additive manufacturing, the researchers created an air jet cooling system in a single component that can direct high-speed air onto multiple electronics hot spots. The researchers manufactured the cooling system from strong polymer materials that can withstand the harsh conditions associated with high-speed air jets. The paper, “Air Jet Impingement Cooling of Electronic Devices Using Additively Manufactured Nozzles,” was published in the journal IEEE Transactions on Components, Packaging, and Manufacturing Technology.
Weisensee Making Big Strides Early in Academic Career
Dr. Patricia Weisensee, formerly of Dr. King’s research group, earned her PhD in mechanical engineering from Illinois in December of 2016, and just one month later, she joined Washington University in St. Louis as an assistant professor. Now leading her own research program, Weisensee studies the interactions of liquids and solids for energy applications. Focusing on experimental studies, most of her research is fundamental and, in turn, has a vast array of possible applications. In this past year, many exciting developments have taken shape for her research group. The lab has had two papers published, with a third in review, and one of those papers even made the cover of the journal, Soft Matter. Weisensee also won National Science Foundation funding to study droplet nucleation and condensation on lubricant infused surfaces, a NASA Early Career Award for the development of a liquid metal heating switch to use on spacecraft, and a grant from the American Chemical Society to study the effect of heat transfer on the development of flow fields in microporous media.
King’s Company Only “Lighthouse” Honoree in The U.S.
Fast Radius, for which MechSE professor Bill King is Chief Scientist, was named a Manufacturing Lighthouse by the World Economic Forum. There were only nine companies worldwide selected for this honor, out of 1,000 companies considered. These Manufacturing Lighthouse companies are using digital manufacturing technologies at scale. Fast Radius was selected because of its ability to accelerate new product development and production, using additive manufacturing and data analytics. It was the only company selected in North America; the others are in Europe and China. Press available here.
