University of Maine · Mechanical Engineering · Advanced Structures and Composites Center

Knowledge and Innovation for Next Generation Manufacturing

The KING Manufacturing Lab develops affordable, accessible manufacturing processes that improve the efficiency and sustainability of making products — bridging advanced additive manufacturing with traditional processes like metal casting.

Our Research Join the Lab
11
Lab Members
8+
Journal Publications
$3.8M+
Funded Research
2023
Founded at UMaine
01

Research

New AM Processes

Rheology-Informed Mixture Engineering for Extrusion AM

Reliable extrusion requires balancing two competing material properties: flowability under pressure and shape retention after deposition. We investigated how particle size distribution (PSD) governs these properties in ceramic aggregate pastes using a custom-built extrusion rheometer. Finer particles produced higher viscosity and wall shear stress due to increased surface area and interparticle friction, while coarser particles offered more consistent, predictable flow. Both mixtures exhibited shear-thinning behavior. This work establishes a rheology-informed framework for designing printable, mineral-based materials for extrusion AM. (Hossain, Moore & King, SFF 2025)

New AM Processes

Binder Jet Additive Manufacturing

Binder jetting is a versatile powder-bed AM process capable of producing complex geometries in metals, ceramics, and sand. Our research investigates binder deposition strategies, powder-binder interactions, and process parameter optimization to improve part quality, expand printable material systems, and reduce the cost and complexity of binder jet systems.

Process Modeling

Modeling of AM Sand Mold Anisotropy

AM parts are inherently anisotropic. We investigate how orientation-dependent density and surface roughness in printed molds affect metal flow and solidification, and integrate AI with simulation to enable generative design for AM sand molds.

Process Modeling

Fiber Distribution in Continuous Forming

We study how processing parameters drive fiber migration and alignment in fiber-filled thermoplastic tapes — building predictive models to enable designed fiber alignment for lightweight, high-strength continuously formed structures.

Large-Format AM

Surface Enhancement for Large-Format AM Tooling

Large-format polymer AM holds promise for reducing tooling lead time and cost across industries from metal casting to boat building. We investigate print strategies, self-leveling coatings, and cladding to improve surface quality and durability in service.

Convergent Manufacturing

Bridging Additive and Traditional Manufacturing

Our overarching vision is convergent manufacturing — integrating additive manufacturing with traditional processes like sand casting and machining to create hybrid workflows that are more efficient, more sustainable, and more accessible than either approach alone.

02

People

Principal Investigator

PK
Dr. Philip King
Assistant Professor, Mechanical Engineering
Email Google Scholar CV

PhD Students

GK
Gihun Kim
PhD Student
Email
SH
S.U.M Rabbi Hossain
PhD Student
Email
CC
Chiara Cardona
PhD Student
Email

Master's Students

TM
Timothy Moore
M.S. Student
Email
TK
Trevor Knoedler
M.S. Student
Email

Undergraduate Researchers

EM
Eric Mabry
Undergraduate Researcher
Email
SR
Sarah Rathbun
Undergraduate Researcher
Email
BM
Benjamin Morgan
Undergraduate Researcher
Email
VD
Veronika Davis
Undergraduate Researcher
Email

Alumni

SM
Samuel Morris
M.S., 2025
GH
Gus Hoy
Undergraduate Researcher · 2025 Goldwater Scholar
DS
Daniel St. John
Undergraduate Researcher
03

Publications

2025
Density and Surface Texture Measurements of 3D Printed Sand to Improve Modeling
Morris, S.* and King, P.
International Journal of Metalcasting, 2025 · AFS Best Additive Manufacturing Paper Award
DOI ↗
2025
Effect of Novel Riser Design Using 3D Sand-Printing on the Defects and Mechanical Performance of a Casting
Shuvo, M.M., Skiadopoulos, M., Shahed, K.S., King, P., et al.
Journal of Manufacturing Processes, 2025
DOI ↗
2025
Rheology Informed Mixture Engineering of Aggregates for Extrusion Additive Manufacturing
Hossain, S.*, Moore, T.*, and King, P.
Solid Freeform Fabrication Symposium – An Additive Manufacturing Conference 2025, Conference Proceedings
PDF ↗
2024
Hands-on Digital Tools for Metalcasting Engineering Education in Foundry Science
King, P., et al.
International Journal of Metalcasting, 2024
DOI ↗
2024
Optimal Design of AM Support Structures for EDM Removal from Build Plate
Bicknell, G., Shahed, K., King, P., et al.
International Journal of Advanced Manufacturing Technology, 2024
DOI ↗
2024
Toward Reducing Casting Defects via 3D Risers via 3D Sand-Printing: A Simulation Study
Shuvo, M., King, P., et al.
International Journal of Metalcasting, 2024
DOI ↗
2023
Novel Experimental Metal Flow Analysis Method for Sand Casting via Additive Manufacturing
King, P. and Manogharan, G.
International Journal of Metalcasting, 2023
DOI ↗
2023
A Novel Approach to Visualize Liquid Aluminum Flow to Advance Casting Science
Bate, C., King, P., Sim, J., and Manogharan, G.
Materials, 2023
DOI ↗
2023
Effect of Freezing Range on Reducing Casting Defects through 3D Sand-Printed Mold Designs
Martinez, D., King, P., Sama, S., Sim, J., Toykoc, H., and Manogharan, G.
International Journal of Advanced Manufacturing Technology, 2023
DOI ↗

* Denotes lab advisee. Full list available on Google Scholar.

04

Contact

Get in touch

We are always looking for motivated graduate students, postdoctoral researchers, and collaborators. If you are interested in our work or in joining the lab, please reach out.

Email philip.king@maine.edu
Phone 207-581-3052
Office Ferland EEDC, Room 218
Address Department of Mechanical Engineering
Advanced Structures and Composites Center
University of Maine, Long Rd.
Orono, ME 04469
Send Message

Or email directly at philip.king@maine.edu — we typically respond within a few days.