FasTech

FasTech LLC, Danville VA
Additive Manufacturing Intern | May 2026 - Auguest 2027
NOTE: Due to the work I did at FasTech being in the defence industry, I cannot get too specific or show photos of my work

Aluminum WAAM Process Development 

The objective of this project was to expand FasTech's aluminum Wire Arc Additive Manufacturing capabilities by developing and validating new processing parameters on an AML3D production system equipped with a Fronius iWave power source. Through a series of experimental builds, the projects goal is to investigate newly available welding modes and process settings to identify stable operating conditions, improve deposition quality, and establish repeatable manufacturing procedures for future aerospace and defense applications.

I planned and executed experimental print campaigns while working alongside manufacturing engineers to evaluate aluminum deposition performance under a range of welding conditions. This included investigating new Fronius iWave capabilities, developing process parameters for stable deposition, documenting manufacturing procedures, and analyzing print quality to support future production work.

Large Scale Manufacturing Feasibility Study 

As Project Manager, I led an engineering feasibility study investigating the manufacture of an large ~40 ton metal component using Wire Arc Additive Manufacturing. The project focused on evaluating whether the component could be produced through large scale additive manufacturing, identifying the equipment and facility requirements needed to manufacture it, and developing a comprehensive technical proposal outlining the manufacturing approach, project timeline, and anticipated engineering challenges.

I coordinated the technical planning and day to day execution of the study while working closely with engineers. My responsibilities included developing manufacturing concepts, evaluating equipment requirements, researching production strategies for extremely large scale components, and contributing to customer proposal documentation.

Other Cool Projects

Throughout my internship, I gained hands-on experience operating industrial Wire Arc Additive Manufacturing systems and supporting day-to-day manufacturing activities. I contributed to experimental magnesium DED Arc printing, an emerging area of additive manufacturing that presents significant challenges due to magnesium’s high reactivity, oxidation behavior, and flammability. Successfully producing magnesium components demonstrated the potential of the process for lightweight aerospace and defense applications.

I also received training in industrial machine shop practices and completed an industry-focused Geometric Dimensioning and Tolerancing (GD&T)  course to strengthen my understanding of engineering drawings, tolerance analysis, inspection, and design for manufacturability.

Additionally, I participated in a DoW-sponsored project kickoff to assess the feasibility, scope, risks, schedule, and execution strategy of a proposed manufacturing effort. I later conducted an on-site audit on behalf of FasTech, reviewing a project partner’s equipment, manufacturing capabilities, quality systems, facility readiness, and ability to support the planned work.