Clayson C. Spackman has extensive experience in 3D printing soft composites and fiber networks. He received his PhD in Mechanical Engineering from Rensselaer Polytechnic Institute where he developed a 3D printing technology for soft composites using inkjet printing and electrospun fibers. His research focused on investigating material failure mechanisms and developing innovative testing protocols. He has published several peer-reviewed articles and led multiple research projects funded by the NSF and DoD involving 3D printing composites, modeling fiber interactions, and developing educational lab modules.

1. Clayson C. Spackman
Email: clay.spackman@gmail.com • Phone: (208) 286-5984
EDUCATION
Rensselaer Polytechnic Institute, Troy, NY 2016
Doctor of Philosophy - Mechanical Engineering GPA: 3.27/4.00
Dissertation Title: “Direct Writing of Fiber Networks for 3D Printing Soft Composites”
Pepperdine University, Malibu, CA 2012
Bachelor of Science - Physics GPA: 3.54/4.00
Minor-Creative Writing
Pepperdine University, Lausanne, Switzerland (Semester Abroad) Spring 2010
TECHNICAL SKILL SETS
Experimental:
 Development of a reliable and scalable 3D printing
technology for soft composite materials
 Investigating fundamental material failure
mechanisms using state-of-the-art metrology
units (Alicona, Zeta Instruments, Zeiss SEM)
 Designed innovative material testing protocols for
nano-scale fibers, nano-ropes, and soft composites
 Inkjet 3D printing using micro-scale piezoelectric
nozzles
 High speed imaging (200k+ frames/s)
 Calibration and validation of FEM/CZM
models with physical experiments
 Micro-scale machining using DT-110 Hybrid
μEDM machine
 SEM analysis of fracture surfaces
 Electrospinning aligned/co-axial/non-
woven/multi-material nanofibers
 Direct-writing of nano-scale fiber structures
Modeling:
 Using cohesive zone modelling (CZM) to model
delamination, crack growth, adhesive bond failure
 Using parametric studies to impact
manufacturing process variables (e.g. peel rate)
 Automated digital image analysis
 Multiphysics finite element modeling (FEM) of
electrospinning production systems
 Simulation of surface roughness
 Creating material failure models (traction-
separation curves)
PEER-REVIEWED PUBLICATIONS
1. Spackman, C., Picha, K., Gross, G., Nowak, J., Smith, P., Zheng, J., Samuel, J., and Mishra, S. “A Novel
Multimaterial Additive Manufacturing Technique for Fabricating Laminated Polymer
Nanocomposite Structures.” J. Micro Nano-Manuf. 3(1), 011008 (Mar 01, 2015) (11 pages)
2. Spackman, C., Frank, C.R., Picha, K., and Samuel J., “3D Printing of Fiber-reinforced Soft Composites:
Process Study and Material Characterization.” Journal of Manufacturing Processes, Vol 23, Aug.
2016, Pages 296–305.
3. Picha, K., Spackman, C., and Samuel J., “Droplet Spreading Characteristics Observed During 3D
Printing of Aligned Fiber-reinforced Soft Composites.” Additive Manufacturing, Vol 12, Part A, Oct.
2016, Pages 121–131.
4. Spackman, C., Ruff, L., Crucetti, J., Chiappone, S., Schadler, L., and Samuel, J. “Research University and
Community College Collaboration Model to Promote Micro Manufacturing Education: Preliminary
Findings.” North American Manufacturing Research Conference: NNMI Mfg. Education & Workforce
Development (June 2016)
5. Spackman, C.C., Nowak F. J., Mills, K.L., and Samuel J., “A Cohesive Zone Model for the Fiber Stamping
Process Encountered During 3D Printing of Fiber-reinforced Soft Composites”, Under review, ASME
Journal of Manufacturing Science and Engineering (Submitted: Dec 2016)

2. RESEARCH EXPERIENCE
Graduate Research Assistant, August 2012 – December 2016
RPI Nano/Micro-scale Manufacturing and Materials Design Laboratory in Troy, NY
Surgeon Training: Synthetic Human Materials by 3D Printing; Funding Agency: U.S. Dept. of Defense
 Objective: Design and build a prototype of a new 3D printer capable of printing laminated
composite parts for applications in surgeon training
o Invented new 3D printing technology which combines inkjet printing with electrospun fibers
o Led 7 student team that developed a novel 3D printing process capable of creating composites
o Aided in writing Phase II grant proposal that was selected by DoD over other applicants
3D Printing of Hierarchical Fiber-Reinforced Soft Composites; Funding Agency: NSF
 Objective: Investigate the fundamental manufacturing science and process-control problems
unique to the 3D printing of Hierarchical Fiber-Reinforced Soft Composites (HFrSCs)
o Designed experiments to evaluate key manufacturing process steps
o Developed a series of experimental and analytical techniques using optical profilometer, micro-
scale tensile testing, and failure analysis to evaluate novel nanocomposites
o Used Scanning Electron Microscope (SEM) to characterize fracture surfaces of failed specimens
Inkjet 3D Printing/Substrate Interaction Study; Funding Agency: National Science Foundation
 Objective: Identify the behavior of liquid droplets on a new surface (nano-fibrous) to aid process
planning for 3D printing of HFrSCs
o Used high-speed imagery to observe droplet-substrate interaction in a parametric study
o Automated digital image analysis techniques using MATLAB program to analyze ~10 TB of data
Finite Element Modeling; Funding Agency: NSF
 Objective: To gain a fundamental understanding of the underlying physical phenomenon present
in a composite layup operation; close the loop by using FEA results to design new mech. system
o Built a multimaterial FEM in ABAQUS; conducted parametric studies for key design variables
o Designed and executed a validation study to confirm modeling results
o Using model-aided design, improved efficiency of stamping process for 3D printing HFrSCs
Electric Field Modeling; Funding Agency: U.S. Dept. of Defense
 Objective: To design the electric field of a nanofiber collection device to improve its efficiency
o Built a multi-material, multiphysics model using COMSOL to evaluate electrode designs
PEDAGOGICAL EXPERIENCE
Advanced Manufacturing Education; Funding Agency: NSF
 Objective: To develop three independent lab modules for graduate/undergrad. students at RPI,
HVCC, and NTU featuring electrospinning, near-field E-jet, and micro-machining
o Led development of conceptual educational framework, content, and assessment tools
o Collected, curated, and analyzed assessment data and fed results into lab module improvements
o Collaborated with a team of 5 interdisciplinary faculty from multiple educational institutions
o Demonstrated abilities to communicate material effectively with several student demographics
RELEVANT SKILLS
 FEM & CAD Platforms: COMSOL (Proficient), ABAQUS (Expert), SolidWorks (Proficient)
 Statistical/Engineering Analysis: MINITAB (Proficient), MATLAB (Expert)
 Programming: C++ (Proficient), G-Code CNC Control (Proficient), LabVIEW (Proficient)
LEADERSHIP ACTIVITIES
Sigma Phi Epsilon, Pepperdine University -Vice President of Recruitment, Mentor of the 10 Year Plan
AmeriCorps - Jumpstart Corps Member Volunteer (Santa Monica, CA)