A research team at Kennesaw State University has found that modifying 3D printing build settings can significantly improve the strength and reliability of printed components. Their findings suggest that a printed part’s performance can be nearly tripled, offering new opportunities for safer and more efficient designs in industries such as nuclear energy.
The project is led by Aaron Adams, assistant chair of the Department of Engineering Technology, with mechatronics engineering student Eric Miller playing a key role. Miller is part of the university’s START Lab in the Southern Polytechnic College of Engineering and Engineering Technology, where he works alongside other students and faculty on simulations, additive manufacturing, and advanced materials research.
Supported by both the Summer Undergraduate Research Program and the Sophomore Scholars Program, their work examines how minor design choices impact the strength of 3D-printed parts. Adams explained how this research could address challenges in nuclear fuel efficiency: “Right now, the fuel is in the form of a pellet about the size of a penny, and the pellets are stacked together like a roll of coins,” said Adams. “These fuel pellets are then placed inside a fuel rod. When the nuclear reaction begins, they heat up, expand, and come into contact with the rod wall. Because they have no room to expand, they must be removed before the fuel is completely depleted, limiting how much of the fuel can be used. Ultimately, we hope to achieve a 15 percent increase in fuel utilization using complex geometries.”
The team is investigating ways to use 3D printing to create internal channels and lattice structures within materials so that there is space for expansion during use—potentially increasing both efficiency and safety.
Miller’s responsibilities include designing models for testing with Finite Element Analysis (FEA), exploring different combinations of lattice angles and densities. He noted that this experience has broadened his understanding beyond what he typically encounters in his mechatronics coursework: “I wanted to get more into the mechanical engineering world because we focus less on that in mechatronics,” Miller said. “Getting into strength of materials and FEA has been a great learning experience.”
He also described his early interest in 3D printing: “When I was younger, I was kind of clumsy and would break things all the time,” he said. “Using a $200 printer and free software, I’ve been able to make replacement parts for things I’ve broken. It really lets me imagine something and then build it at home, even if it’s not as complex as nuclear fuels.”
Running detailed simulations required large amounts of computing power due to complex mesh sizes for curved geometries—a challenge Adams sees as valuable training: “If you sum up our biggest challenge in one word, it’s resources, specifically our ability to run highly computational simulation models,” Adams said. “But I give Eric the task, and he runs with it. He always exceeds expectations.”
Lawrence Whitman, dean of SPCEET at Kennesaw State University, commented on how this work aligns with broader institutional goals: “This is the kind of real-world research we champion,” Whitman said. “Eric and Dr. Adams are developing solutions that contribute to national energy security and strengthen the future of manufacturing.”
Miller will present their findings at an upcoming American Society of Mechanical Engineers conference. Reflecting on his involvement in research so far he stated: “Even when something appears to be a failure, it’s still a success because it tells us what direction not to take,” he said. “I’ve really appreciated this experience, and it’s been incredibly helpful for my growth.”
