James Haller, a recent mechanical engineering master’s graduate, is helping streamline the complex process of large-scale 3D printing. Once seen as a tool strictly for prototyping and aesthetic modeling, 3D printing has come a long way, now building houses, boats, and even bridges. As revolutionary as additive manufacturing (AM) has become, it’s far from a ‘push-to-print’ process. This is especially true when working with advanced or bio-based materials that are essential for making large-scale prints durable, lightweight, and sustainable.
Each new print job begins with careful calibration of the chosen material. This involves dialing in processing temperatures, screw speeds, deposition rates, and more. Material calibration is a process that can be lengthy and highly specialized. Currently, much of this calibration depends on the expertise of a few skilled operators. Without them, production can grind to a halt. Haller and Jason Stevens, a research scientist on the ASCC’s Advanced Manufacturing Operations Team, are working to change that.
James Haller
Haller is a University of Maine alum, earning his B.S. in Engineering Physics in 2016 and his master’s in mechanical engineering this past May 2025. After completing his bachelor’s, he spent time traveling and working across the U.S. before returning to Maine to begin his engineering career. Haller has been with the Advanced Structures and Composites Center (ASCC) for five years.
He began his work at the ASCC on a collaborative project with the U.S. Army Engineer Research and Development Center (ERDC), exploring post-fabrication thermoforming of long fiber thermoplastic composites- using heat to reshape compression molded panels into structural forms. Reshaping panels post consolidation allows for the creation of stronger, more complex shapes without extra molds or tools, saving time and materials. Haller transitioned to working with additive manufacturing and short fiber reinforced materials, where he’s focused on streamlining the process of introducing and adjusting new materials for 3D printing.
Haller notes that during his time here, he has contributed to several projects under the ASCC’s collaboration with ERDC. The most recent being the ARP (Accelerated Rapid Prototyping) program. The ARP program aims to improve the quality and reliability of 3D-printed parts by reducing the need for lengthy inspection and certification before parts can be put to use. To make this possible, ASCC researchers are developing ‘smart’ 3D printers equipped with sensor integration, AI, and high-performance computing. These additions would allow the printer to monitor prints in real-time, detecting defects and correcting them on the go.
Haller, alongside Stevens, are developing a method to streamline the onboarding of printer feedstocks for Large Area Additive Manufacturing (LAAM). Their goal is to allow operators to quickly determine the ideal printing parameters like temperature, speed, and the maximum heat that a previously printed layer (substrate) can withstand before receiving a new one.
To achieve this, Haller explains, “we’re trying to start at basically square one” .The team begins by identifying a broad “processing window”, a range of settings that produce at least acceptable print quality. From there, they systematically test combinations of variables such as feed rate, screw RPM, and extruder temperature, evaluating the strength and consistency of each result.To determine the maximum substrate, the point at which previously printed material begins to deform under new heat, James and his team are using heated compression testing. All this data will then be used to define the best settings across different materials and geometries.
Although this study is still in its early stages, this work will have a significant impact on the additive manufacturing industry. By reducing the time and trial-and-error required to onboard new materials, this process could make additive manufacturing faster, more efficient, and more accessible. If this is successful, we’ll see additive manufacturing “being better accepted and adopted by industry,” James notes.
Haller and Stevens will present their work, titled “Heated Compression Testing to Reduce Calibration Costs in the Onboarding of Fiber-Reinforced Feedstocks for Large Area Additive Manufacturing via Thermoplastic Extrusion” at the Composites and Advanced Materials Expo (CAMX) 2025, in Orlando, Florida, on Tuesday, September 9 at 2 PM. Click here for more information about CAMX 2025.
The GEM FOF, the world’s largest thermoplastics 3D printer.
Looking ahead, James is especially excited about the opportunity to experiment with the ASCC’s newest large-scale printer, the Factory of the Future (FOF), once the GEM building opens. He looks forward to “being able to control, use and learn how to experiment on our large printers,” he says. He also hopes to grow on the business and leadership side of the industry; he’s currently pursuing an MBA to complement his technical background.
When asked what he’d say to a student looking to join the ASCC, James reflects: “You wouldn’t think the cutting edge of science and technology research would be happening right here in Central Maine, but it is.”
