Matthew (Matt) Frank

Title(s):

John B. Slater Professor of Sustainable Design & Manufacturing, Professor
Industrial & Manufacturing Systems Engineering

Office

3023 Black Engr.
2529 Union Dr.
Ames, IA 500112030

Information

Education

  • PhD, Pennsylvania State University, Industrial Engineering, 2003
  • MS, Pennsylvania State University, Mechanical Engineering, 1998
  • BS, Pennsylvania State University, Mechanical Engineering, 1996

Curriculum Vitae

Interest Areas

Dr. Frank’s research focuses on creating new methods for rapid manufacturing that can create functional parts at nearly the push of a button. The major goal of the research is to eliminate the pre-process engineering time and skill required to create a custom component. Therefore, the term rapid means fast and easy process planning, fixture planning and setup planning for making one, or several functional parts.  A particular focus of Dr. Frank’s research is on Hybrid Manufacturing, which is a combination of Additive Manufacturing (e.g. 3D printing) and Subtractive Manufacturing (e.g. CNC machining).   His work has been applied to the manufacturing of industrial components, rapid pattern tooling for metal castings, and even custom bone implants.  More recently, his lab is re-deploying some of the process planning algorithms into new Design for Manufacturability (DfM) software solutions.  He has received the SME Outstanding Young Manufacturing Engineer Award, the Don Grant Award for Excellence in Teaching, and currently holds two US Patents. For more information on Rapid Manufacturing see the lab web page: The Rapid Manufacturing and Prototyping Laboratory (RMPL)

Publications

Weflen, E. + and Frank, M.C., “Mechanical Root Structure for Multi-material Hybrid Additive and Subtractive Manufacturing”, Rapid Prototyping Journal, https://doi.org/10.1108/RPJ-06-2020-0142  Chen, N. and Frank, M.C., “Design for Manufacturing: geometric manufacturability evaluation for 5-axis milling”, Journal of Manufacturing Science and Engineering, Transactions of the ASME, 143 (8): 081007, 2021  Abdel-All, E.S. +, Frank, M.C and Stone, R.T., “Design for Manufacturability-Based Feedback to Mitigate Design Fixation”, Journal of Mechanical Design, Transactions of the ASME, 140 (9):10.1115/1.404024, 2018  Chen, N. +, Barnawal, P. +, and Frank, M.C., “Automated Post Machining Process Planning for a New Hybrid Manufacturing Method of Additive Manufacturing and Rapid Machining”, Rapid Prototyping Journal, Vol. 24, No. 7, pp. 1077-1090, 2018 Abdel-All, E.S. +, Frank M.C., and Stone, R.T., “A Study of Design Fixation Related to Additive Manufacturing” Journal of Mechanical Design, Transactions of the ASME, 140 (4), 041702, 2018 Eldakroury, M.A. +, Chen, N. +, and Frank, M.C., “A New Method for Locating Candidate Substrates for Multi Axis Hybrid Manufacturing Systems”, Rapid Prototyping Journal, Vol. 24, No. 2, pp 237-248, 2018 Hoefer M.J. + and Frank, M.C., “Automated Manufacturing Process Selection During Conceptual Design” Journal of Mechanical Design, Transactions of the ASME, 140 (3), 031701, 2018 Wang, D. +, Peters, F.E., and Frank, M.C., “A Semiautomatic, Cleaning Room Grinding Method for the Metal casting Industry”, Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 139, pp 121017-1:121017-8, 2017 Barnawal, P. +, Dorneich, M.C., Frank, M.C., and Peters, F.E., “Evaluation of Design Feedback Modality in Design for Manufacturability”, Technical Brief, Journal of Mechanical Design, Transactions of the ASME, Vol. 139, No 9, 094503, 2017 Hou, G. +, and Frank, M.C., “Computing the Global Visibility Map Using Slice Geometry for Setup Planning”, Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 139, No. 8, 081006, 2017 Zhu, S. +, Magnussen, C.J. +, Judd, E+, Frank M.C., and Peters, F.E., “Automated Composite Fabric Layup for Wind Turbine Blades”, Journal of Manufacturing Science and Engineering, Vol 139, No. 6, 061001, 2017 Abdel-All, E. +, Frank M.C., and I. Rivero, “Rapid Tooling Using Friction Stir Welding and Machining”, Rapid Prototyping Journal, Vol 23, issue 1, pp. 81-95, 2017 Lei, S. +, Frank, M.C., Anderson, D.D., and Brown, T.D., “A Method to Represent Heterogeneous Materials for Rapid Prototyping – The Matryoshka Approach”, Rapid Prototyping Journal, Vol. 20, Issue 5, 2014 Luo, X. +, Li, Y. +, and Frank, M.C., “A Finishing Cutter Selection Algorithm for Additive/Subtractive Rapid Pattern Manufacturing”, International Journal of Advanced Manufacturing Technology, Vol 69, pp. 2041-2053, 2013 Li, Y. + and Frank, M.C., “Computing Axes of Rotation for Setup Planning Using Visibility of Polyhedral CAD Models”, Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 134, pp 041005(1-10), 2012 Anderson DD, Thomas TP, Frank M.C., Marsh JL, Brown TD. On the Horizon from the ORS: “Assessing and minimizing the adverse mechanical consequences of articular fractures to decrease the risk for posttraumatic osteoarthritis”. Journal of the American Academy of Orthopaedic Surgeons, 19(10), pp. 644-646, 2011 Thomas, T.P., Anderson, D.D., Willis, A.R., Liu, P., Frank, M.C., Marsh, J.L., and Brown, T.D., “A Computational/Experimental Platform for Investigating Three-Dimensional Puzzle Solving of Comminuted Articular Fractures”, Computer Methods in Biomechanics and Biomedical Engineering, Vol. 14, No. 3, pp. 263-270, 2011 Petrzelka, J.E. +, Frank, M.C., “Advanced Process Planning for Subtractive Rapid Prototyping”, Rapid Prototyping Journal, Vol. 16, No. 3, pp. 216-224, 2010 Makhe, A. + and Frank, M.C., “Polygon Subdivision for Pocket Machining Process Planning”, Computers and Industrial Engineering, Vol. 48, No. 4, pp. 709-716, 2010 Yang, Z., Wysk, R.A., Joshi, S.B., Frank, M.C., Petrzelka, J.E. +, “Conventional Machining Methods for Rapid Prototyping and Direct Manufacturing”, International Journal of Rapid Manufacturing, Vol. 1, No. 1, pp. 41-64, 2009 Luo, X. + and Frank, M.C., “A Layer Thickness Algorithm for Additive/Subtractive Rapid Manufacturing”, Rapid Prototyping Journal Vol.16, No. 2, pp. 100-115, 2009 Boonsuk, W. + and Frank, M.C., “Automated Fixturing for a Rapid Machining System”, Rapid Prototyping Journal Vol. 15, No. 2, pp. 111-125, 2009 Li, Y. + and Frank, M.C., “Computing Non-Visibility of Convex Polygonal Facets on the Surface of a Polyhedral CAD Model”, Computer Aided Design, Vol. 39, No. 9, pp. 732-744, 2007 Li, Y. + and Frank, M.C., “Machinability Analysis for 3-axis Flat End Milling”, Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 128, No. 2, pp. 454-464, 2006 Frank, M.C. #, Wysk, R.A., and Joshi, S.B., “Determining Setup Orientations from the Visibility of Slice Geometry for Rapid CNC Machining”, Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 128, No. 1, pp. 228-238, 2006 Frank, M.C. #, Wysk, R.A., and Joshi, S.B., “Rapid Planning for CNC Machining – A New Approach to Rapid Prototyping”, Journal of Manufacturing Systems, SME, Volume 23, No. 3, pp. 242-255, 2004 Frank, M.C.#, Joshi, S.B., and Wysk, R.A., “Rapid Prototyping as an Integrated Product/Process Development Tool: An overview of Issues and Economics”, Journal of Chinese Institute of Industrial Engineers, Vol. 20, No. 3, 2003

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