Daniel Walczyk

Professor and Director, Center for Automation Technologies and Systems (CATS)
Mechanical, Aerospace and Nuclear Engineering
walczd
http://www.rpi.edu/~walczd/
Education: 

Ph.D. Massachusetts Institute of Technology

Focus Area: 
Rapid Tooling|X|Environmentally Conscious Design|X|Machine Design
Bio: 

Daniel F. Walczyk, Ph.D., PE is a Professor of Mechanical Engineering in the Department of Mechanical , Aerospace, and Nuclear Engineering and also Associate Director of Manufacturing for the Center of Automation Technologies and Systems. He received a B.S. from Syracuse University in 1986, a M.S. from Rensselaer Polytechnic Institute in 1991, a P.E. License from New York State in 1994 and a Ph.D. from Massachusetts Institute of Technology in 1996, all in mechanical engineering. Prior to his graduate work, Dr. Walczyk worked for seven years industry, primarily with the GE, as a mechanical design engineer. Since becoming an academic in January 1996, he has received several awards and honors including a DAAD Fellowship (1995), NSF Faculty Early CAREER Development Award (1998), Loctite Corporation Summer Engineering Faculty Fellowship (1998), and a Presidential Early Career Awards for Scientists and Engineers (1999), SAE Ralph R. Teetor Educational Award in the Aerospace Category (2000), and ASME Fellow (2011). He is also a holder of five U.S. patents and two pending.

Publications: 
Walczyk, D. and Kuppers, J., “Thermal Press Curing of Advanced Thermoset Composites,” Composites Part A: Applied Science and Manufacturing (In Press).|X|Walczyk, D., Kuppers, J. and Hoffman, C., “Curing and Consolidation of Advanced Thermoset Composite Laminate Parts by Pressing Between a Heated Mold and Customized Rubber-Faced Mold,” J. Manuf. Sci. Eng., Volume 133, Issue 1, February 2011, 011002 (7 pages).|X|Walczyk, D.F. and Sangra, J.S., “A Feasibility Study of Ribbon Architecture for PEM Fuel Cells,” ASME Journal of Fuel Cell Science and Technology, Vol 7, No. 5, Oct. 2010, pp. 051001-1–8.|X|Harris, T.A.L., Walczyk, D.F., and Weber, M., “Manufacturing of High-Temperature Polymer Electrolyte Membranes – Part I: System Design and Modeling,” ASME Journal of Fuel Cell Science and Technology, Vol. 7, No. 1, Feb. 2010, pp. 011007-1–9.|X|Harris, T.A.L., Walczyk, D.F., and Weber, M., “Manufacturing of High-Temperature Polymer Electrolyte Membranes – Part II: Implementation and System Model Validation,” ASME Journal of Fuel Cell Science and Technology, Vol. 7, No. 1, Feb. 2010, pp. 011008-1–8.|X|Harris, T. A. L.; Walczyk, D., "Study on the Rheological Behavior of High Temperature Polymer Electrolyte Member Solutions" Journal of Applied Polymer Science, Vol. 111, No. 3, 2009, pp. 1286-92.|X|Walczyk, D.F. and Ziomek, W, “An Inexpensive Weight Bearing Indicator with Load Range Capability for Rehabilitation of Patients with Lower Extremity Injuries,” ASME Journal of Medical Devices, Vol. 3, No. 3, Sept. 2009, pp. 031001-1–10.|X|Walczyk, D.F. and Yoo, S., “Design and Fabrication of a Laminated Thermoforming Tool with Enhanced Functionality,” Journal of Manufacturing Processes, Vol. 11, 2009, pp. 8-18.|X|Walczyk, D.F. and Munro, C.B., “Design of an Active Reconfigurable Fixturing Device using a Bed of Pins Lowered on a Moving Platen,” ASME Journal of Manufacturing Science and Engineering, Vol. 129, No. 2, April 2009, pp.021009-1-12.|X|Walczyk, D., Ordway, N., Mann, K., and Ziomek, W., “Progress on Clinical Trials and Product Development of a Simple, Inexpensive Feedback Device for Patients Requiring Partial Weight Bearing,” (Abstract), ASME Journal of Medical Devices, Vol. 2, No. 2, June 2008, p.027528.|X|Munro, C.B. and Walczyk, D.F., “Reconfigurable Pin-type Tooling: A Survey of Prior Art and Reduction to Practice,” ASME Journal of Manufacturing Science and Engineering, Vol. 129, No. 3, June 2007, pp. 551-565.|X|Yoo, S. and Walczyk, D., “An Adaptive Slicing Algorithm for Profiled Edge Laminae Tooling,” International Journal of Precision Engineering and Manufacturing, Vol. 8, No. 3, July 2007, pp. 64-71.|X|Yoo, S. and Walczyk, D.F., “Sealing and Heat Transfer Performance of Conformal Channels and Cooling Fins in Laminated Tooling,” ASME Journal of Manufacturing Science and Engineering, Vol. 129, No. 2, April 2007, pp. 388-399.|X|Walczyk, D.F. and Bartlet, J.P., “An Inexpensive Weight Bearing Indicator Used for Rehabilitation of Patients with Lower Extremity Injuries,” ASME Journal of Medical Devices, Vol. 1, No. 1, March 2007, pp. 38-46.|X|15. Williams, R.E., Walczyk, D.F., and Hoang, T.D., “Using Abrasive Flow Machining to Finish and Seal Conformal Channels in Laminated Tooling, “ Rapid Prototyping Journal, Vol. 13, No. 2, 2007, pp. 64-75.|X|16. Harris, T.A. and Walczyk, D.F., “Development of a Casting Technique for Membrane Material Used in High Temperature PEM Fuel Cells,” SME Journal of Manufacturing Processes, Vol. 8, No. 1, 2006, pp. 19-31.|X|17. Zha, P., Walczyk, J.J., Griffith-Ross, D.A., Tobacyk, J. and Walczyk, D.F., “The impact of cutlure and individualism-collectivism on the creative potential and achievement of American and Chinese adults,” Creative Research Journal, Vol. 18, No. 3, 2006, pp. 355-366.|X|Yoo, S. and Walczyk, D.F., “An Advanced Cutting Trajectory Algorithm for Laminated Tooling,” Rapid Prototyping Journal, Vol. 11, No. 4, 2005, pp. 199-213.|X|Yoo, S. and Walczyk, D.F., “Advanced Design and Development of Profiled Edge Lamination Tooling,” SME Journal of Manufacturing Processes, Vol. 7, No. 2, 2005, pp. 162-173.|X|Walczyk, D.F. and Im, Y.T., “Structural Modeling of Profiled Edge Laminae (PEL) Tools,” ASME Journal of Manufacturing Science and Engineering, Vol. 127, No. 1, 2005, pp.138-147.|X|Shook, J.T., and Walczyk, D.F., “Structural Modeling of Profiled Edge Laminate (PEL) Tooling using the Finite Element Method,” ASME Journal of Manufacturing Science and Engineering, Vol. 126, No. 1, 2004, pp.64-73.|X|Walczyk, D.F., Hosford, J., and Papazian, J., “Using Reconfigurable Tooling and Surface Heating for Incremental Forming of Composite Aircraft Parts,”ASME Journal of Manufacturing Science and Engineering, Vol. 25, No. 2, May 2003, pp. 333-343.|X|23. Im, Y.T., and Walczyk, D.F., “A CNC Cutting Trajectory Algorithm for Profiled Edge Laminated Tooling,” Rapid Prototyping Journal, Vol. 8, No. 5, 2002, pp.290-299. (Note: Received “Highly Commended Award” for 2002 volume of this journal)|X|Im, Y.T. and Walczyk, D.F., “Development of a Computer-Aided Manufacturing System for Profiled Edge Lamination Tooling,” ASME Journal of Manufacturing Science and Engineering, Vol. 124, No. 3, August 2002, pp. 754-761.|X|Walczyk, D.F., and Vittal, S., “Bending of Titanium Sheet Using Laser Forming,” SME Journal of Manufacturing Processes, Vol. 2, No. 4, 2000, pp. 258-269.|X|Walczyk, D.F., and Longtin, R.S., “Fixturing of Compliant Parts Using a Matrix of Reconfigurable Pins,” ASME Journal of Manufacturing Science and Engineering, Vol. 122, No. 4, Nov. 2000, pp. 766-772.|X|Im, Y.T., Walczyk, D.F., Schwarz, R.C., Papazian, J., “A Comparison of Pin Actuation Schemes for Large-scale Discrete Dies,” SME Journal of Manufacturing Processes, Vol. 2, No. 4, 2000, pp. 247-257.|X|Walczyk, D.F., and Im, Y.T., “A Hydraulically-actuated Reconfigurable Tool for Flexible Fabrication: Implementation and Control,” ASME Journal of Manufacturing Science and Engineering, Vol. 122, No. 3, Aug. 2000, pp. 562-567|X|Walczyk, D.F., and Raju, V., “Simplifying the Development and Usage of Fixtures for Sheet Metal and Composite Aircraft Parts,” ASME Journal of Manufacturing Science and Engineering, Technical Brief, Vol. 122, No. 2, May 2000, pp. 370-3|X|Walczyk, D.F., Raju, V., and Miller, R., “Fixture-less Assembly of Sheet Metal Parts for the Aircraft Industry,” Proceedings of the Institution of Mechanical Engineers: Journal of Engineering Manufacture (Part B), Vol. 214, 1999, pp. 173-182.|X|Walczyk, D.F. and Hardt, D.E., “A Comparison of Rapid Fabrication Methods for Sheet Metal Forming Dies,” ASME Journal of Manufacturing Science and Engineering, Vol. 121, No. 1, May 1999, pp. 214-224.|X|Misiolek, W. Z., Walczyk, D.F., and Rock, S.J., “Rapid Prototyping and Rapid Tooling Methods for Metal Forming,” Rudy i Metale, R 43, No. 5, 1998, pp. 619-625.|X|Walczyk, D.F. and Hardt, D.E., “Design and Analysis of Reconfigurable Discrete Dies for Sheet Metal Forming,” SME Journal of Manufacturing Systems, Vol. 17, No. 6, 1998, pp. 436-454.|X|Walczyk, D.F., Lakshmikanthan, J., and Kirk, D., “A Reconfigurable Tool for Forming Aircraft Body Panels,” SME Journal of Manufacturing Systems, Vol. 17, No. 4, 1998, pp. 287-296.|X|Walczyk, D.F., and Hardt, D.E., “Rapid Tooling for Sheet Metal Forming using Profiled-Edge Laminations—Design Principles and Demonstration,” Journal of Manufacturing Science and Engineering, Vol. 120, No. 4, Nov. 1998, pp. 746-754.|X|Prakah-Asante, K.O., Walczyk, D., and Craig, K., “Single-Axis Servomechanism for Control Experiments including Joint Friction, Backlash, Compliance, and Structural Flexibility,” Journal of Engineering Design, Vol. 5, No. 1, 1994.|X|Prakah-Asante, K.O., Islam, A.S., Walczyk, D.F., and Craig, K., “Design, Construction and Testing of a Single-Axis Servomechanism for Control Experiments involving Coulomb Friction, Backlash and Joint Compliance,” Journal of Engineering Design, Vol. 4, No. 4, 1993.