From rubble to rockets
ASU researcher’s DARPA-funded project is set to redefine design-to-use paradigms
Assistant researcher scientist Pu Han holds a prototype of an extrusion 3D printing tool head end-effector, which enables the creation of polymer and composite components with mechanical properties and surface finishes similar to those produced by injection molding. Photographer: Aisha Kaddi/ASU
Researchers at ASU are pushing the limits of technological innovation and productivity by developing a self-sustaining manufacturing framework that will ultimately reduce costs and waste.
Keng Hsu, an associate professor of manufacturing engineering in the School of Manufacturing Systems and Networks, part of the Ira A. Fulton Schools of Engineering at Arizona State University, is leading a project funded by the Defense Advanced Research Projects Agency, or DARPA, to develop manufacturing solutions for high-pressure environments where materials and resources may be limited.
Funded by a $7 million grant spanning 36 months, this initiative will develop a critical new process that integrates material informatics, advanced processing and innovative techniques. The result will be an analytical framework designed to eliminate production barriers in high-demand manufacturing environments.
ASU is one of the few academic institutions being awarded this type of funding.
Doctoral student Shams Torabnia (left) and project lead Associate Professor Keng Hsu (right) discuss the contact mechanics and material deformation during a rolling contact evaluation, a key aspect of material processing. Photographer: Aisha Kaddi/ASU
A new approach to forward production
The project centers around a shift toward decentralized, on-demand production, enabling components to be manufactured locally rather than relying on centralized facilities. This design-to-use process addresses supply chain vulnerabilities by facilitating rapid fabrication in resource-limited or high-risk environments.
This framework analyzes unconventional raw material to determine its properties and best usage, thereby reducing pre-production time, shipping delays and reliance on external supply chains. This technology, which Hsu refers to as having the potential to one day turn “rubble to rockets,” could also significantly reduce manufacturing costs.
Unlike predictive approaches, this adaptive approach doesn’t prescribe specific materials to meet a goal; instead, it identifies what can be achieved with the available resources.
At the core of this innovation are advanced computational tools and algorithms that interpret data to make quick, informed decisions during production. By analyzing both physical materials and their digital counterparts, the framework generates customized solutions tailored to the unique demands of each situation.
The goal is to integrate Hsu’s final framework into a deployable container where a person can load material at the front, request a specific end product and let the system assess how to create that product using the available material, ultimately delivering a finished product in the end.
The Rapid and Responsive Design to Degital-manufacturing team poses for a photo.
Addressing national needs
Hsu’s project is a key part of DARPA’s broader initiative to tackle pressing national security challenges. With the agency’s support, Hsu and his team are developing a self-contained manufacturing system capable of performing reliably in some of the most extreme environments — from the battlefield to deep space. This technology is intended to not only strengthen military operations but also offer transformative benefits for civilians in critical situations.
“DARPA’s role has been essential,” Hsu says. “They are pushing the boundaries of what’s possible, funding innovative ideas and helping scale the resulting solutions.”
By integrating advanced computational tools and algorithms, the system can evaluate and process both physical materials and their digital data, creating tailored solutions in real time. This innovation maximizes operational efficiency, providing rapid responses in dynamic, resource-constrained environments.
“We are aiming to build a framework that can adapt to new challenges and evolving demands,” Hsu says. “This flexibility will reduce waste, optimize sustainability and ultimately create more reliable solutions.”
A researcher holds up a badge showing the R2D2 team logo. Photographer: Aisha Kaddi/ASU
The bigger picture
The project is in its early phase, with the research team setting ambitious goals for the next three years. A key milestone is demonstrating the system’s initial capabilities, a crucial step that will lay the foundation for refining the technology, scaling it for broader use and testing its performance in various environments.
“We see this as an opportunity to not only advance technology but also to train the next generation of leaders who can navigate these complex and interdisciplinary challenges,” Hsu says.
While Hsu and his team have a clear direction, they recognize the challenges of transitioning from a conceptual design to a fully operational system. Although the task is substantial, the potential benefits are clear.
The R2D2 project team poses in Keng Hsu’s lab. From left to right: Keng Hsu, ASU associate professor and principal investigator; Nathan Fonseca, doctoral student; Shams Torabnia, doctoral student; Pu Han, research scientist; Neel Garde, undergraduate student; Faisal Riyad, doctoral student; and Mohamed Abbas, research and development engineer. Photographer: Aisha Kaddi/ASU
Hsu’s research highlights the importance of collaboration between academia, industry and government in addressing complex challenges. The partnership between ASU, SRI International, TRIEX and DARPA demonstrates how universities can play a key role in developing practical solutions with wide-ranging applications.
“The work we’re doing here is laying the groundwork for the next generation of manufacturing technology,” Hsu says.
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