Mechanical and Aerospace Engineering News

In the MADLab at Michigan Tech, 3D printers hum as troll figurines with long tresses smile down from shelves, drone wings sprouting synthetic hair whisper through revolutions, small balloonlike inflatables are tested for their surprising strength, and a jar of grape jelly sits on a shelf—proof of the cost-effective research happening here. (We’ll explain in a minute.)

The lab founder is Bhisham Sharma, whose research addresses the intersection of structural mechanics, dynamics, and acoustics. Sharma joined Michigan Tech’s department of Mechanical and Aerospace Engineering as an associate professor in August 2023. Prior to joining Tech, he was an assistant professor in the Department of Aerospace Engineering at Wichita State University, 2016. He brought the lab and several student researchers with him when he came to MTU.

The MADLab aims to understand the fundamental mechanics of advanced structured material systems and leverage this understanding to create new technologies for aerospace and mechanical applications. It also seeks to have a transformative impact on global society through accessible and inclusive scientific research and education.

The MADLab at Michigan Tech includes two NSF Graduate Research Fellows; a NASA Jumpstart Fellow; and undergraduate, graduate, and postdoc researchers—all working in a facility that may live up to its name.

That’s because Sharma’s lab reflects his educational philosophy. Here are a few of his favorite lessons:

Inspiration is everywhere

Aerogels are a class of synthetic materials that are produced by extracting the liquid component of a gel and replacing it with gas, resulting in an extremely lightweight material which can be up to 99.98% air by volume. Though aerogels have found applications in thermal blankets and as energy absorbers, their uses have been limited due to their fragility and lack of control over their macrostructure.

Aerogels also look a lot like freeze-dried cat treats.

Feeding a hungry cat in the Sharma household was the unlikely inspiration for a new project: using additive manufacturing to create stronger, more consistent aerogels. The MADLab’s aerogel research has led to new products and new manufacturing technologies. “That’s the beauty of being at a university—you can experiment first with an end goal of finding a useful solution,” says Sharma.

To attract the best students, be unique

Sharma believes it’s easier to attract, retain, and motivate students with unique projects, and the MADLab student team speaks to that philosophy.

PhD candidate Will Johnston first learned about 3D printing as a sophomore at Wichita State. Johnston began working with Dr. Sharma as an undergraduate researcher, experimenting with new methods of creating long, hair-like fibers using 3D printers. Johnston and Sharma looked to nature for potential applications for these fibers. They landed on owls, which are nearly silent when they fly due to the unique structure of their feathers. 

Johnston, now at Michigan Tech, is PI on the AeroFeathers project, which uses 3D printing to fabricate biomimetic blades. These blades could be used to make drones, fans, HVAC systems, and industrial settings quieter. The MADLab student team was awarded $80,000 from the NASA University Student Research Challenge (USRC). They’ll use the award for fabrication, testing, and data analysis of AeroFeathers while embarking in a public crowdfunding campaign. AeroFeathers also won an honorable mention in the aerospace and defense category of the 2023 SAE Create the Future Design contest.

Don’t artificially constrain your research interests

The MADLab’s research is broad-ranging for a reason. They’re doing additive manufacturing with synthetics, ceramics, and aerogels. Creating TenseFlatables, stronger versions of lightweight inflatable devices often used in the aerospace industry. Using a mathematical concept discovered around 190 BCE to design a new class of phononic structures. And much more. By embracing the discovery mindset inherent at universities, and the interests of his students, Sharma’s MADLab is producing groundbreaking results in a wide variety of fields. 

The lab sidesteps budgetary constraints by finding low-cost solutions whenever possible. 

“Low costs mean you can experiment a lot more,” says Sharma. “If you break something, it’s no big deal.” For example, finding a way to 3D print with ceramics could be a boon to the aerospace industry. But traditional 3D printers use solid plastic, and ceramics begin as a hot liquid and dry to a solid. So when the MADLab was challenged to convert a typical printer into a low-cost direct ink writing printer that prints with liquids, they needed a cheaper way to prove the concept. Printing grape jelly onto a piece of bread was a cheap (and delicious) first-round solution. 

Play Jelly Printing at Michigan Tech video

Jelly Printing at Michigan Tech

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3D printing with jelly is a cost-efficient way to test 3D printing liquids.

These projects and others in Sharma’s MADLab reflect his educational philosophy: the joy of university work comes from helping top-tier student talent grow their skills while having the autonomy to pursue broad fields of research as new ideas and technologies come along.

About the College of Engineering

Michigan Tech’s College of Engineering offers more than 15 bachelor of science degrees in biomedical engineering, chemical engineering, civil, environmental and geospatial engineering, electrical and computer engineering, engineering fundamentals, geological and mining engineering and sciences, manufacturing and mechanical engineering and technology, materials science and engineering, and mechanical and aerospace engineering. 

Our engineering graduate degree options include master’s and PhD programs, along with robust online certificate programs for busy professionals. Follow Michigan Tech Engineering on Facebook, Instagram, LinkedIn, and Twitter for the latest happenings.