Swapnil Sinha
Ph.D. Candidate
Mechanical Engineering
The Pennsylvania State University
I am a researcher in the field of Design for Additive Manufacturing (3D Printing). I work on experimental, and computational modelling of the 3D printing process to predict part strength. I teach heat transfer laboratory course to seniors in Mechanical Engineering department at Penn State. I also hold a Masters in Engineering Design – Product Design track from Penn State.

My Research

Design Heuristics for In-Situ Embedding with 3D Printing

The process of in-situ embedding of components in 3D printed parts enables manufacturing of volume- and material- efficient multifunctional products possible. In this project, I experimentally explored impact of embedding process on part strength, and developed design heuristics for good quality embedded parts.

Predicting Polymer Material Part Strength through Recorded Thermal Profile

Polymer welding at an interface can be predicted with polymer rheology and thermal profile of the interface. In this project, I applied this theory on 3D printed parts by obtaining thermal profiles at layer interfaces and utilizing polymer rheology.

Heat Transfer Simulation of Material Extrusion AM to Predict Part-Strength

The fundamental science of Heat Transfer and Polymer chemistry allows prediction of material behavior at molecular level, that controls bulk material properties. Through this project I explore computational physics based modelling of 3D printing process to predict part strength.

Automating Digital (CAD) design for 3D printing Embedded components

In this project, I automated optimized design of cavities for complex geometry components, that otherwise requires high level digital design and 3D printing knowledge.

Developing Wind Tunnel set-up for heat transfer laboratory to experiment on cooling in 3D Printed microchannels

Under the capacity of teaching assistant for the Heat Transfer laboratory course, I conceptualized, designed, and prototyped a wind tunnel set-up to test heat transfer and pressure drop in unique 3D printed micro-channels. This set-up is currently being used to enable remote learning experience for the students taking the laboratory course.

Journal Publications

Conference Publications

Education Highlights

The Pennsylvania State University

University Park, PA



2017 - Now



2015 - 2017

Manipal Institute of Technology

Karnataka, India



2011 - 2015

Achievement Highlights

Winner of “All-Terrain Vehicle” Competition
Manipal Institute of Technology, Karnataka, India
Member of Society of Women Engineers
Best Poster award in undergraduate exhibition
Penn State University
2019 & 2020
NSF student support recipient
Solid Freeform Fabrication (SFF) Symposium, Austin, TX
Rising Stars in Mechanical Engineering
Stanford University

Recent Highlights

The Art And Science Of Predicting Polymer 3D Printed Part Strength

Sarah Goehrke • October 27, 2020

The Journey From Making To Mechanical Engineering To Additive Manufacturing PhD

Sarah Goehrke • October 27, 2020