Stephen J. Rock

Dr. Stephen Rock is a Senior Research Scientist in the NYS Center for Automation Technologies and Systems at Rensselaer Polytechnic Institute. He earned a B.S. in Electrical Engineering from Union College in 1989, an M.S. in Computer & Systems Engineering from Rensselaer Polytechnic Institute in 1991, and a Ph.D. in Computer & Systems Engineering from Rensselaer in 2000. Steve serves as lab director for the CATS' Additive Manufacturing Lab, and he leads projects and conducts research on information-driven manufacturing process development - often involving advanced technologies such as laser systems, industrial robotics, and ultrasonic processing. Steve began work in Additive Manufacturing in 1989 on CAD/CAM interfacing, model validity checking, automated repair, topology-based slicing, and creation of an improved file format for storing facet model data. Steve invented and patented a powder-based metal additive manufacturing process, and he applied finite element modeling techniques and powder sintering models to perform shape optimization and correct for process-induced geometric distortions introduced during powder consolidation. Steve leads metal additive manufacturing R&D within the CATS and serves on the NY State Additive Manufacturing Steering Committee jointly organized by NYSERDA and ESD/NYSTAR. Steve has also been re-elected to the Robotic Industries Association board of directors and chairs the RIA Education Committee.

Beyond Additive Manufacturing, Steve has conducted research on manufacturing process improvements for fuel cell membrane electrode assembly production. Results of this work have been commercialized and fielded on manufacturing lines in Germany and the United States. Steve participated on the team that proposed, won, and developed several courses for an NSF sponsored IGERT in the Engineering, Science, and Entrepreneurship of Fuel Cells, and he participated on the multi-year DOE project entitled Adaptive Process Controls and Ultrasonics for High Temperature PEM MEA Manufacture. He served as a Subject Matter Expert on the ONR-sponsored Fuel Cell Manhattan Project, and he has conducted numerous projects related to manufacturing process energy efficiency and energy management algorithm development.

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