Matthew (Matt) Frank
Title(s):
C.G. “Turk” and Joyce A. Therkildsen Department Chair
Industrial & Manufacturing Systems Engineering
Office
2209A Therkildsen Industrial Engineering Building
531 Bissell Road
Ames, IA 50011-1096
Information
Education
- PhD, Pennsylvania State University, Industrial Engineering, 2003
- MS, Pennsylvania State University, Mechanical Engineering, 1998
- BS, Pennsylvania State University, Mechanical Engineering, 1996
Research
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, fixture, tooling, and setup planning for making one, or several functional parts. A particular focus of Dr. Frank’s research is on Hybrid Manufacturing, which is the 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, custom bone implants, and Design for Manufacturability (DfM) software solutions.
Curriculum Vitae (PDF)
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
Weflen, E., Hamilton, J.D., Sorondo, S., Harrysson, O., Frank, M.C. & Rivero, I.V., (2022): “Evaluating interlayer gaps in friction stir spot welds for rapid tooling applications”, IISE Transactions, DOI:10.1080/24725854.2022.209118, 2022
Weflen, E. + and Frank, M.C., “Hybrid additive and subtractive manufacturing of multi-material objects”, Rapid Prototyping Journal, 20(10), pp. 1860-1871 https://doi.org/10.1108/RPJ-06-2020-0142, 2021
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
Primary Strategic Research Area
Advanced Materials & Manufacturing