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Building with air – how nature ��. hole-filled blueprints shape manufacturing

hugginsm — Thu, 05 Feb 2026 17:29:24 +0000

Building with air – how nature ��. hole-filled blueprints shape manufacturinghugginsm February 5, 2026

Professor Anne Schmitz examines the influence of the natural world on engineering and additive manufacturing.

This article appeared in TechXplore and others, and originated from The Conversation, an independent and nonprofit source of news, analysis and commentary from academic experts.

If you break open a chicken bone, you won’t find a solid mass of white material inside. Instead, you will see a complex, spongelike network of tiny struts and pillars, and a lot of empty space.

It looks fragile, yet that internal structure allows a bird ��. wing to withstand high winds while remaining light enough for flight. Nature rarely builds with solid blocks. Instead, it builds with clever, porous patterns to maximize strength while minimizing weight.

Cross-section of the bone of a bird ��. skull: Holes keep the material light enough that the bird can fly, but it ��. still sturdy. Steve Gschmeissner/Science Photo Library via Getty Images

Human engineers have always envied this efficiency. You can see it in the hexagonal perfection of a honeycomb, which uses the least amount of wax to store the most honey, and in the internal spiraling architecture of seashells that resist crushing pressures.

For centuries, however, manufacturing limitations meant engineers couldn’t easily copy these natural designs. Traditional manufacturing has usually been subtractive, meaning it starts with a heavy block of metal that is carved down, or formative, which entails pouring liquid plastic into a mold. Neither method can easily create complex, spongelike interiors hidden inside a solid shell.

Bird bones, seashells and honeycombs use clever, porous designs to stay strong without the extra weight. Now, 3D printing is letting engineers copy those natural blueprints.

The sustainable future

Beyond performance, mimicking nature ��. less-is-more approach is a significant win for sustainability. By “printing air” into the internal structure of a product, manufacturers can use significantly less raw material while maintaining the necessary strength.

As industrial 3D printing becomes faster and cheaper, manufacturing will move further away from the solid-block era and closer to the elegant efficiency of the biological world. Nature has spent millions of years perfecting these blueprints through evolution – and engineers are finally learning how to read them.

The invisible architecture

That paradigm changed with the maturation of additive manufacturing, commonly known as 3D printing, when it evolved from a niche prototyping tool into a robust industrial force. While the technology was first patented in the 1980s, it truly took off over the past decade as it became capable of producing end-use parts for high-stakes industries like aerospace and health care.

3D printing makes it far easier to manufacture lightweight, hole-filled materials. kynny/iStock via Getty Images

Instead of cutting away material, printers build objects layer by layer, depositing plastic or metal powder only exactly where it ��. needed based on a digital file. This technology unlocked a new frontier in materials science focused on mesostructures.

A mesostructure represents the in-between scale. It is not the microscopic atomic makeup of the material, nor is it the macroscopic overall shape of the object, like a whole shoe. It is the internal architecture, including the engineered pattern of air and material hidden inside.

It ��. the difference between a solid brick and the intricate iron latticework of the Eiffel Tower. Both are strong, but one uses vastly less material to achieve that strength because of how the empty space is arranged.

If engineers wanted to make a part stronger, they generally had to make it thicker and heavier. This approach is often inefficient, wastes material and results in heavier products that require more energy to transport.

I am a mechanical engineer and associate professor at the University of Wisconsin-Stout, where I research the intersection of advanced manufacturing and biology. For several years, my work has focused on using additive manufacturing to create materials that, like a bird ��. wing, are both incredibly light and capable of handling intense physical stress. While these “holey” designs have existed in nature for millions of years, it is only recently that 3D printing has made it possible for us to replicate them in the lab.

From the lab to your closet

While the concept of using additive manufacturing to create parts that take advantage of mesostructures started in research labs around the year 2000, consumers are now seeing these bio-inspired designs in everyday products.

The footwear industry is a prime example. If you look closely at the soles of certain high-end running shoes, you won’t see a solid block of foam. Instead, you will see a complex, weblike lattice structure that looks suspiciously like the inside of a bird bone. This printed design mimics the springiness and weight distribution found in natural porous structures, offering tuned performance that solid foam cannot match.

Engineers use the same principle to improve safety gear. Modern bike helmets and football helmet liners are beginning to replace traditional foam padding with 3D-printed lattices. These tiny, repeating jungle gym structures are designed to crumple and rebound to absorb the energy more efficiently than solid materials, much like how the porous bone inside your own skull protects your brain.

Testing the limits

In my research, I look for the rules nature uses to build strong objects.

For example, seashells are tough because they are built like a brick wall, with hard mineral blocks held together by a thin layer of stretchy glue. This pattern allows the hard bricks to slide past each other instead of snapping when put under pressure. The shell absorbs energy and stops cracks from spreading, which makes the final structure much tougher than a solid piece of the same material.

I use advanced computer models to crush thousands of virtual designs to see exactly when and how they fail. I have even used neural networks, a type of artificial intelligence, to find the best patterns for absorbing energy.

My studies have shown that a wavy design can be very effective, especially when we fine-tune the thickness of the lines and the number of turns in the pattern. By finding these perfect combinations, we can design products that fail gradually and safely – much like the crumple zone on the front of a car.

By understanding the mechanics of these structures, engineers can tailor them for specific jobs, making one area of a product stiff and another area flexible within a single continuous printed part.

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Building with air – how nature ��. hole-filled blueprints shape manufacturing

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Robert F. Cervenka School of Engineering

The Robert F. Cervenka School of Engineering focuses on enhancing the learning experience for students in ��'s engineering programs.

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Hero Caption: Engineers use structures found in nature – like the honeycomb – to create lightweight, sturdy materials.

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Degree: Ph.D. Biomedical Engineering

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�� . packaging program ranks among top 10 in national listings for its polytechnic approach

goersab — Tue, 03 Feb 2026 14:00:00 +0000

�� . packaging program ranks among top 10 in national listings for its polytechnic approachgoersab February 3, 2026

Applied learning, strong industry partnerships benefit students, create clear career pathways

Abbey Goers

�� . B.S. packaging program has been recognized by three national ranking authorities in their annual listings:

College Raptor: No. 3 for 2026
Universities.com: No. 9 for 2026
College Factual: No. 5 for 2025

“We are honored to be recognized as one of the top packaging programs in the nation,” said Associate Professor Min DeGruson, program director. “�� . distinction comes from our polytechnic approach of hands-on, applied learning, our deep and long-standing industry partnerships and our strong career focus.”

DeGruson said students with an interest in design, engineering, problem-solving and sustainability can find wonderful careers in the packaging field. In the end, every product needs a package — meaning every industry needs packaging engineers, she said.

�� packaging graduates achieve 100% job placement with an average starting salary of $70,000. Located near the Twin Cities and Wisconsin ��. Fox Valley, two major hubs for packaging innovation, �� offers unparalleled access to packaging suppliers and career opportunities across the food, consumer products and medical device industries.

Recent employers of graduates include 3M, Bosch, Boston Scientific, General Mills, Great Northern Corporation, Kimberly Clark, Medtronic, Milwaukee Tool, Post Consumer Brands, Sartori Cheese, Target and more.

�� . award-winning Cooperative Education & Internship Program helps students connect with placement opportunities to gain additional career-readiness skills before graduation. More than a third of students accept positions after graduation with their internship employer.

Students begin working in five dedicated packaging labs in their first semester, spending more than half of their coursework engaged in lab-based testing, materials research, prototyping, and design verification alongside faculty and peers.

“With our dedicated labs, a rich program history, and a highly engaged alumni network, our students benefit from exceptional industry support and clear career pathways. These strengths are reflected in our outcomes,” DeGruson said.

Cross-disciplinary research and projects are another highlight of education at ��, as well as the Great Northern Corp. Collaboration Experience course, in which students design packaging for a Great Northern client.

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“Packaging students work alongside students from the graphic communications, and graphic design and interactive media, industrial and product design and video production programs,” Associate Professor Kate Liu said. “We offer students multiple development paths to maximize their potential for success, including design, management, sustainability, business, medical packaging, food packaging, quality control, manufacturing, sales and supply chain.”

The program ��. dedicated faculty, including three professors and an adjunct professor with diverse expertise, ensures students are well-prepared for their careers. “We have excellent instructors and small class sizes that allow students to develop key skills for success,” added Provost Glendalí Rodríguez.

In addition to her faculty role, DeGruson is chair of the Food Packaging Division under the Institute of Food Technologists and is an Executive Committee member of Kilmer Innovation in Packaging. Liu recently worked with Madison-based Tricky Foods to identify sustainable insulation options to safely ship charcuterie and cheese boards coast to coast.

Students have the opportunity to join the Stout Packaging Association. They also participate in and are frequently awarded for their designs at national and international student competitions, including the Paperboard Packaging Alliance, International Molded Fiber Association, Flexible Packaging Association and 48HR REPACK, created by the Institute of Packaging Professionals. A team of students even won a competition sponsored by Kellanova, a division of Kellogg ��., and the Packaging Association of Canada, for their redesign of the iconic Pringles packaging.

�� is the only school among the Universities of Wisconsin that offers a bachelor ��. in packaging. Schools that ranked first and second in each list are Michigan State University and Clemson University.

�� also offers a minor in sustainability and a B.S. plastics engineering, in which faculty and students research how the plastics industry can be more sustainable, including by using more recycled materials.

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Min DeGruson

Research Interests: My research focuses primarily on synthesis and characterization of bio-based polymers for food packaging applications, and using nanotechnology to improve their mechanical, thermal, and barrier properties with additional functions such as antimicrobial property.

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Degree: Ph.D. Food Packaging/Food Science

University: Pennsylvania State University

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�� Online engineering, education, management programs ranked among best by U.S. News & World Report

giffeyt — Mon, 02 Feb 2026 14:00:00 +0000

�� Online engineering, education, management programs ranked among best by U.S. News & World Reportgiffeyt February 2, 2026

Annual rankings recognize bachelor ��. and master ��. programs for helping students advance education, career goals

Tom Giffey

Returning to school as an adult student balancing work, family or military responsibilities is a daunting challenge. �� . Stout Online gives students the flexibility, affordability and support necessary to succeed in the face of this challenge, and in doing so has once again been ranked among the Best Online Programs by U.S. News & World Report.

Stout Online helps working professionals begin or complete their degrees or advance their career goals through more than 30 online bachelor ��. and graduate programs, as well as dozens of certificates, certifications, individual courses and development opportunities.

According to the just-released 2026 rankings from U.S. News, Stout Online offers some of the Best Online Programs in the state, region and nation. �� ranked No. 3 among all public universities in Wisconsin and Minnesota for its bachelor ��. in management and leadership and its master ��. in education and engineering programs. These programs also attained the following rankings:

Best Online Bachelor ��. in Business Programs: No. 26 in the Midwest, No. 88 nationwide.
Best Online Master ��. in Education Programs: No. 36 in the Midwest, No. 133 nationwide.
Best Online Master ��. in Engineering Programs: Top 19 in the Midwest, No. 79 nationwide.

Provost Glendalí Rodríguez

“With more than 1,300 online students, we understand that working professionals are balancing academic pursuits with many other responsibilities,” said Provost Glendalí Rodríguez, vice chancellor of Academic Affairs. “Through flexible online offerings, we work to meet students where they are. Given �� . polytechnic mission, we facilitate relevant, career-focused education to help working professionals increase their advancement opportunities and skills.”

U.S. News evaluates online programs based on a variety of factors, including student engagement, faculty credentials, and services and technologies. Now in its 14th year, the U.S. News Best Online Programs is designed for individuals looking to complete or further their education. This year ��. edition evaluated more than 1,800 online bachelor ��. and master ��. degree programs using metrics specific to online learning. The rankings include only degree-granting programs offered primarily online by regionally accredited institutions.

Stout Online furthers students’ careers

�� faculty are experienced industry experts dedicated to teaching the latest in technology and trends in their fields. Small cohorts build close communities and share a wealth of diverse perspectives to enhance each other ��. learning.

M.S. Manufacturing Engineering Online

Do you want to improve your ability to respond to the needs of modern manufacturing? Advance in your career with your online degree.

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Students in the online M.S. in manufacturing engineering program, part of �� . Robert F. Cervenka School of Engineering, enhance their professional skills through assignments and projects that apply to real-life industry problems. They build expertise in continuous process improvement, lean manufacturing, project management and manufacturing engineering processes. Students may also choose to earn a Six Sigma Black Belt Certificate to meet the degree ��. elective requirements.

M.S. Education

Take your career in education further and enhance your impact on students' lives.

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The online M.S. in education is a 30-credit degree program built around a core of 18 teaching and applied research credits, with a selection of 12 elective credits to meet students’ career interests. While meeting those elective requirements, students may earn one of a number of professional certificates or certifications, including Autism Spectrum Disorder Specialist, Instructional Design, Math Specialist, Reading Specialist or Teaching Adult Learners.

�� . School of Education also offers online master ��. programs in school counseling and career and technical education as well as an Ed.D. in career and technical education leadership.

B.S. Management & Leadership

Our B.S. Management & Leadership program is designed to open new doors to advance your career through industry-enhanced classes and real-world experiences.

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�� . online bachelor ��. in management and leadership program, offered through the School of Management, has been ranked No. 10 among the best online programs by BestAccreditedColleges.com. It offers eight concentrations to help professionals reach their career goals, including business leadership studies, community-based service management, finance and accounting, human resource management, operations management, project management, quality management, risk control and safety management, and supply chain management.

�� graduates are in demand, with 99% employed or pursuing additional degrees within six months of graduation, a figure that rises to 100% among graduates of the three online programs honored by U.S. News. Those who received graduate degrees from �� had an annual starting salary of $74,000. Meanwhile, the average starting salary for recipients of �� undergraduate degrees was $57,000, according to the university ��. most recent First Destination Report.

For its dedication to affordability and student outcomes, �� has earned national recognition as one of America ��. Best Colleges by Money Magazine for two years in a row.

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All stacked up: Ashley Furniture-sponsored project results in ‘better product’ developed by engineering seniors

goersab — Mon, 05 Jan 2026 13:50:00 +0000

All stacked up: Ashley Furniture-sponsored project results in ‘better product’ developed by engineering seniorsgoersab January 5, 2026

Student team builds functional nonstandard pallet stacker to be implemented, replicated in company ��. facilities

Abbey Goers

A team of engineering students at �� designed an innovative nonstandard pallet stacker for Arcadia-based Ashley Furniture, which plans to quickly implement the machine in its facilities.

Within their Senior Design Experience II capstone course, the team was tasked with building a machine that could lift and hold 6-foot-long, 100-pound pallets off the ground until a stack of 12 was collected. Made of quarter-inch steel, the stacker can support 1,800 pounds, a 125% increase of Ashley ��. requested 1,400 maximum stack weight.

Once the stack is complete, the system lowers it to the floor for removal with an electric pallet jack. The stacker – which is 10 feet long, 8 feet wide and 4 feet tall – can be operated by a single person and has a maximum cycle time of 40 seconds.

Erik Kramer, Chase Rodewald, Luke Mertens, Riley Stiehl and Zachary Morgan.

The student team is Luke Mertens, a double major in manufacturing and mechanical engineering from Blue Earth, Minnesota; manufacturing engineering major Zachary Morgan of Eau Claire; and mechanical engineering majors Chase Rodewald of Lake City, Minnesota, and Riley Stiehl of Alma.

During the Manufacturing Engineering & Mechanical Engineering Showcase on Dec. 16, they presented a scaled, controls-focused prototype to �� faculty and supporters, as well as Ashley representatives, including Manufacturing Engineer Erik Kramer, the team ��. project manager.

“The �� team built a better system, a better product for us. And with a final product price of about $25,000, their solution offers us a cost reduction of about 60%,” Kramer said. “Now, with the team ��. documentation, our automation team can replicate their functional design to build six more stackers for our facilities.”

Riley Stiehl (left) and Chase Rodewald (right) present the Ashley Furniture nonstandard pallet stacker.

The team will submit their accompanying documents and the full-size machine, which includes an emergency stop for user safety, to Ashley for integration into the company ��. operations. Final assembly will be completed at Ashley, when safety curtains will be installed around the machine as well.

Reverse-engineering to build a better product

The two-semester-long project began last spring, when the team had a site visit to Ashley to meet with Kramer and other staff. Ashley had purchased a stacker from a third party, but there were aspects of the machine that Kramer and staff didn’t like.

“We needed the Stout team to find a way to reverse-engineer the machine to have it function as we needed it to,” Kramer said.

A digital SolidWorks model of the Ashley Furniture nonstandard pallet stacker.

The team developed schematics in SolidWorks software and a small-scale model, which they presented to Ashley in May. Ashley purchased the materials needed to build the prototype as well as the final product.

“We’re no different than a real engineering team. Everyone is working together, but we each have niche roles based on our strengths,” said Mertens, who led the team ��. controls and instrumentation. Morgan was the CNC machinist and completed the documentation and organization of project records. Rodewald and Stiehl managed the manual assembly, machining and welding.

While some of the parts were cut and machined at Ashley, the team also completed the machining and welding of parts in �� . Fryklund Hall labs.

Chase Rodewald (left) and Riley Stiehl (right) assemble the Ashley Furniture nonstandard pallet stacker prototype.

“There ��. a lot to be done, so it ��. nice to have multiple people working on it together,” Stiehl said. “We relied on Ashley ��. industry equipment and experience. Having them cut and machine parts, rather than going to a third source, was a lot more cost-effective and saved a lot of time. And we could also use our own skills right in the labs on campus.”

Electrical and welding breakthroughs

During the first phase of their project, the team ��. biggest challenge was how to meet one of the requirements set by Ashley: using electrical power, rather than pneumatics or hydraulics, to lift the pallets.

“Because most electrical motors are rotational based, it limits your options for linear motion, or the straight-line and up-and-down motion we needed for the pallet stacker,” Rodewald said. “We achieved this through a linear actuator, which is a device that converts a motor ��. rotational energy into linear motion.”

Luke Mertens works on the controls for the Ashley Furniture nonstandard pallet stacker prototype.

The electrical power matches Ashley ��. capabilities and can be implemented immediately on the shop floor by pulling in power from overhead sources, instead of the company having to install tanks to support a fluid power device.

During the project ��. second phase, the team was challenged by how to weld some of the individual pieces before final assembly. The gussets – a three-part support structure, for example – needed to self-align at a 90-degree-angle to make it easier for Rodewald and Stiehl when welding the pieces together.

“We devised a self-aligning slot and tab mechanism, so the parts would basically hold themselves in place,” Stiehl said.

A side-by-side comparison of a digital model and a welded gusset.

“Breakthroughs often come just after the moment you feel you’ve exhausted every option,” Mertens added.

Engineering students use a project management methodology called a “stage gate process,” which includes built-in briefs and reviews at key points in the design and build process. It also allows for feedback from their classmates, professors and project sponsors.

“The process is very helpful because it allows you to review the current aspects of your design, so you never get too far down a rabbit hole,” Mertens said. “The feedback allows for a varying array of perspectives from your rough draft to the final draft of your concept.”

Zachary Morgan (left) and Luke Mertens (right) present a prototype of the Ashley Furniture nonstandard pallet stacker.

This fall semester, the Ashley capstone team was just one of a dozen teams composed of about 50 engineering students working on Capstone I and II projects in Fryklund Hall labs.

Mertens, Morgan, Rodewald and Stiehl earned their degrees and crossed the commencement stage on Dec. 20, among a class of 527 Stout Proud graduates.

According to the university ��. most recent First Destination Report, 99% of 2023-24 graduates from the mechanical and manufacturing engineering programs reported they were either employed or continuing their education within six months, with an average starting salary of $72,000.

�� . Robert F. Cervenka School of Engineering is home to five ABET-accredited programs that also include computer and electrical engineering, engineering technology and plastics engineering, as well as a sixth bachelor ��. program in packaging. A master ��. in manufacturing engineering is available on campus or online.

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Building with air – how nature ��. hole-filled blueprints shape manufacturing

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Inspiring Graduate: Luke Mertens, B.S. Manufacturing Engineering, B.S. Mechanical Engineering

goersab — Tue, 23 Dec 2025 16:45:00 +0000

Inspiring Graduate: Luke Mertens, B.S. Manufacturing Engineering, B.S. Mechanical Engineeringgoersab December 23, 2025

Hired before graduation as a controls engineer at SMC Ltd.

Inspiring Graduate: Luke Mertens (’25)

Hometown: Blue Earth, Minnesota
Degree: B.S. Manufacturing Engineering; B.S. Mechanical Engineering
Minor: Advanced Automation & Robotics

Luke Mertens chose �� for its polytechnic education and hands-on learning opportunities that would build his skillset through internships and industry-sponsored projects to make him career-ready before graduation.

Luke Mertens earned his manufacturing and mechanical engineering degrees from �� on Dec. 20, 2025.

Mertens earned a double major in manufacturing engineering and mechanical engineering and crossed the commencement stage on Dec. 20 as one of 527 �� graduates. He was hired before graduation as a controls engineer at SMC Ltd., a medical device contract manufacturer in Somerset.

“My main responsibilities will include designing electrical schematics, wiring control panels, and specifying electrical components for machines that will be built by the in-house automation department,” he said.

“I hope to make an impact in my field by contributing to complex problem solving and challenging what is possible in the world of automation.”

How has �� prepared you to work in your field?

�� has helped make me an industry-ready undergraduate by offering hands-on learning and teaching me how to identify, break down and solve problems.

Luke Mertens was hired before graduation as a controls engineer at SMC Ltd.

My favorite lab experiences were my Controls and Robotics labs, where I learned all about industrial automation. My favorite internship was at Midwest Manufacturing in Eau Claire, where I worked as a manufacturing engineer and spent my time programming and troubleshooting automation.

I also completed a two-semester, industry-sponsored capstone project with a team of engineering students to build a pallet-lifting machine for Ashley Furniture. The machine can lift and hold 6-foot-long, 100-pound pallets off the ground until a stack of 12 is collected.

All stacked up: Ashley Furniture-sponsored project results in ‘better product’ developed by engineering seniors

Student team builds functional nonstandard pallet stacker to be implemented, replicated in company ��. facilities

What stands out about your �� experience?

What stands out to me about the �� experience is how you are not just a number, but rather a person. I have thoroughly enjoyed many of my professors and the professional relationships I formed with them throughout my collegiate journey.

It was nice to take hands-on classes, where I always had resources available to help tailor my learning to what I needed and answer questions that I had.

The only thing that limits your growth at �� is your own individual willingness to learn. You will have all the resources you need to succeed.

Luke Mertens in the Material Removal Lab in Fryklund Hall.

How did your campus involvement impact your experience?

I was an offensive lineman with Blue Devils football for four years and was a part of football ��. FCA (Fellowship of Christian Athletes) group for four years.

In the 2024 season, my fourth year, I was a team captain. I was also named to the second-team All-WIAC, with 11 of my teammates; and the National Football Foundation Hampshire Honor Society, with 15 of my teammates.

I have been a part of Stout ��. Society of Manufacturing Engineers student organization.

What challenges did you face in earning your degree and how did you overcome them?

I am proud of my personal growth and my ability to adapt and overcome a variety of challenges, including my biggest: time management. Being as involved as I was in extracurricular activities made me prioritize how I spent my time.

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Hired before graduation as a controls engineer at SMC Ltd. Luke Mertens, Fall Commencement 2025

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Inspiring Graduate: Zachary Morgan, B.S. Manufacturing Engineering

goersab — Tue, 23 Dec 2025 16:40:00 +0000

Inspiring Graduate: Zachary Morgan, B.S. Manufacturing Engineeringgoersab December 23, 2025

Joining Andersen Windows & Doors’ Engineering Rotational Program to improve processes and empower people

Inspiring Graduate: Zachary Morgan (’25)

Hometown: Eau Claire
Degree: B.S. Manufacturing Engineering

After several years working in critical care nursing and later in a warehouse at Andersen Windows, Zachary Morgan realized he wanted to be on the side of improving systems, not just adapting to them.

Zachary Morgan earned his manufacturing engineering degree from �� on Dec. 20, 2025.

“�� . strong reputation for applied learning and industry partnerships is what ultimately drew me here to the manufacturing engineering program,” he said. “Years ago, I initially avoided Stout because I was intimidated by the math involved in engineering. I came back to school with a new perspective and a determination to learn.”

For excellence and achievements during his internships, Morgan, of Eau Claire, is a two-time recipient of the university ��. Outstanding Cooperative Education and Internship Program Student of the Year Award and the singular 2024 nominee for the National Co-op Student Achievement Award.

“As an engineering intern at Andersen Windows & Doors for three consecutive summers across two different plants, my responsibilities evolved each year as my skills and experience grew. Stout offered the perfect balance of hands-on experience and real-world relevance, and it became the bridge that allowed me to transform my career path,” he said.

Morgan earned his manufacturing engineering degree and crossed the commencement stage on Dec. 20 as one of 527 �� graduates. He is joining Andersen Windows & Doors’ Engineering Rotational Program, which will allow him to continue growing with a company he deeply respects.

Engineering seniors recognized for intern contributions at Andersen Windows, Darley

Morgan, Taylor making continuous improvements to empower employees, build better industries

“The program is designed to expose engineers to multiple facets of the business, from process optimization to product design and operations leadership. I see it as an ideal next step to strengthen my technical and leadership skills while discovering where I can make the greatest impact long-term,” Morgan said.

“I hope my story inspires others, especially those navigating career changes or self-doubt, to take that step forward. Growth happens when we lean into discomfort and keep learning,” he added.

How do you hope to make an impact in your field?

I hope to bring a human-centered perspective to engineering, designing systems that improve safety, reduce waste, and make daily work more manageable for the people who use them.

To me, meaningful engineering goes beyond solving technical problems; it ��. about empowering people.

I want to help create workplaces where efficiency and empathy coexist, where improvements benefit both productivity and the wellbeing of employees. Over time, I aim to contribute to a culture of continuous improvement, one that values collaboration, curiosity, and purposeful innovation.

How has �� prepared you for your field?

�� has been instrumental in preparing me for my career in manufacturing engineering. The university ��. applied learning model allowed me to translate classroom theory into practical experience through labs, simulations and hands-on projects.

Zachary Morgan is joining Andersen Windows & Doors’ Engineering Rotational Program.

Courses in lean manufacturing, capstone and quality engineering closely mirrored the work I did during my internships at Andersen Windows. Professors encourage not just technical mastery, but also communication, teamwork and leadership, skills that are critical in real industrial environments.

Stout taught me how to think critically, approach challenges methodically, and lead with both data and empathy.

What was your internship experience like at Andersen Windows & Doors?

As an engineering intern at Andersen Windows & Doors, I began by conducting time studies and waste assessments, which gave me a strong foundation in process analysis and data-driven improvement. In my following internship, I focused on enhancing efficiency within the Value-Added Services (VAS) mulling area, a crucial part of the company ��. customization process. This included developing a new rack system, redesigning the layout, and implementing 5S standards to improve organization and workflow.

Most recently, I designed and built a Statistical Process Control (SPC) dashboard that presented real-time quality data in a clear, intuitive way, empowering operators to make faster, more informed decisions and improving overall plant quality.

Through these projects, I learned that small, thoughtful changes can produce meaningful, measurable results. Most importantly, the experience taught me that lasting improvement comes from observation, collaboration, and the courage to question and refine existing processes.

What stands out about your �� experience?

What stands out most about my experience at �� is the incredible culture of support and mentorship. Professors here don’t just teach; they genuinely invest in their students’ growth and take time to connect classroom lessons to real-world applications.

A perfect example of that is when Dr. Slupe spent an hour and a half out of his busy workday helping me to troubleshoot CNC programming for a capstone project. It wasn’t during office hours, and I wasn’t even in one of his classes at the time; he simply wanted to help me learn. That kind of dedication exemplifies what makes Stout special.

The combination of strong academics, approachable faculty, and opportunities like internships, capstone projects and industry collaborations truly sets this university apart.

I’ve found tremendous value in team-based projects that mirror professional settings; those experiences taught me as much about leadership, communication, and adaptability as they did about technical problem-solving and design.

All stacked up: Ashley Furniture-sponsored project results in ‘better product’ developed by engineering seniors

Student team builds functional nonstandard pallet stacker to be implemented, replicated in company ��. facilities

I completed a two-semester, industry-sponsored capstone project with a team of engineering students to build a pallet-lifting machine for Ashley Furniture. The machine can lift and hold 6-foot-long, 100-pound pallets off the ground until a stack of 12 is collected.

How did your involvement on and off campus impact your experience?

I was honored to be selected as one of �� . 2023 and 2024 Outstanding Cooperative Education and Internship Program Student of the Year Award recipients, and later as the university ��. nominee for the National Cooperative Education Student Achievement Award. These recognitions mean a great deal to me because they reflect not only personal growth but also the value of Stout ��. hands-on, applied learning approach.

Beyond academics, I’ve been actively involved in Celebrate Recovery, where I help facilitate group sessions that support individuals in their personal healing and growth journeys. I also volunteer with Fierce Freedom, a nonprofit organization that raises awareness about human trafficking and advocates for victims. They recently launched a new resource called Intersections, which provides powerful educational tools and community connections to combat human exploitation. It ��. an extremely impactful platform that I highly recommend exploring.

These experiences outside the classroom have helped me grow as a leader and advocate, strengthening my empathy and sense of purpose. They’ve reminded me that meaningful impact often begins not with large gestures, but with service, compassion and a commitment to helping others.

What challenges did you face in earning your degree and how did you overcome them?

Zachary Morgan, Co-op award winner.

Returning to school for a second degree while balancing work and life responsibilities was not easy. There were times when the coursework felt overwhelming, especially as I re-engaged with subjects like advanced math and physics after being away from academia for years.

What helped me push through was perseverance, mentorship and a mindset shift. I stopped striving for perfection and started focusing on progress. Support from professors, peers, and my family kept me grounded and motivated through every challenge.

What are you most proud of as you finish your degree?

I’m most proud of how far I’ve come in redefining my career and myself. I started this journey unsure if I could succeed in a demanding engineering program, and now I’m stepping into a profession that excites and challenges me daily. I’m proud not just of the technical skills I’ve gained, but of the resilience and confidence I’ve developed along the way.

I’m deeply grateful for ��, for Andersen Windows and for every mentor, professor and peer who encouraged me along the way. My journey has shown me that it ��. never too late to start over or to pursue something that feels out of reach.

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Joining Andersen Windows & Doors’ Engineering Rotational Program to improve processes and empower people Zachary Morgan, Fall Commencement 2025

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Inspiring Graduate: Isaac Harnack, B.S. Plastics Engineering

goersab — Tue, 23 Dec 2025 16:30:00 +0000

Inspiring Graduate: Isaac Harnack, B.S. Plastics Engineeringgoersab December 23, 2025

Hired before graduation as a GaMra Composites engineer

Inspiring Graduate: Isaac Harnack (’25)

Hometown: Crystal, Minnesota
Degree: B.S. Plastics Engineering

In high school, Isaac Harnack, of Crystal, Minnesota, wanted to follow in his grandfather ��. footsteps and be a mechanic for tractors and large farm equipment. “I have always had a mechanically inclined mind, and machines just make sense to me,” he said.

However, after looking at different career prospects, Harnack ��. mom encouraged him to apply to ��, as one of her friend ��. sons had graduated from the packaging program.

“I took one look at the School of Engineering majors and stumbled upon the plastics engineering program. After seeing an injection molding machine for the first time, I knew that this was the path forward. I had never seen anything like it before and wanted to know its every function.

Isaac Harnack earned his plastics engineering degree from �� on Dec. 20, 2025.

“On top of this, Stout ��. polytechnic spirit drew me closer to the school, as every class is hands-on constantly, you aren’t just learning theory. Here, using industry-standard equipment is just another Tuesday. The fact that making mistakes is encouraged as a point of learning is what kept me here,” he said.

Harnack completed two internships: one at Graco, in Rogers, Minnesota, and one at RTP Company, in Winona, Minnesota. He earned his plastics engineering degree and crossed the commencement stage on Dec. 20 as one of 527 �� graduates. He is starting a new position as an engineer at GaMra Composites.

Harnack is fascinated by injection molding, which really boils down to two subcategories: making and designing the tools that run in the machines or processing the tools that run in the machines, he explained.

“I want to be a processing engineer, as the ‘thinking on your feet’ aspect is where I thrive. This would mean taking a tool and setting up machine parameters to run parts for my company or dealing with processing issues as they occur,” he said.

How do you hope to make an impact in your field?

Plastic is often given a bad rap, as most people only think about plastic as waste. However, it is a good alternative for making things cheaper and better for consumers if it is properly executed. If I can apply the skills I’ve learned in waste-saving measures to my company, it could have a global impact on our no-waste initiatives.

Because I am environmentally conscious, most of the projects that I undertook during my internships were about reducing waste in the injection molding or post-consumer recycling aspect of the process. This was achieved by putting waste product back into the injection molding cycle, which allowed the parts to be made more cheaply and with greater environmental consciousness.

Isaac Harnack in the Plastics Engineering Lab.

Most people may not realize that plastic isn’t infinitely recyclable like aluminum, and it will break down over periods of time, so another project I got to work on was sourcing new additives to restore plastic ��. strength in the post-consumer recycling business. The main goal was to revitalize old plastic and help cut down on waste with new additives to restore chemical bonds.

How has �� prepared you to work in your field?

Stout helped make my internships possible by having job fairs with applicable job sites for my major. The Midwest is a plastic manufacturing hub, and companies are constantly looking for students with plastic engineering experience under their belts. I was lucky enough to have two internship experiences.

Not all schools require an internship experience to graduate, which makes Stout students and graduates that much more desirable to companies.

For my Graco internship, the hands-on machining classes, the understanding of plastic polymers, and how the injection molding machines work really helped highlight my knowledge of these processes to my boss and fellow interns. However, because this was not a plastic-focused internship, I did a lot more manufacturing-style tasks, which opened my eyes to the other side of the engineering world and helped me better understand how that industry works. Instead of working on the processes, I was making tools to automatically remove parts from the machines and cut back on labor. This experience allowed me to understand what I can do to help other engineers have an easier time collaborating on projects with me. I have been in their position, and I know what I want to hear to solve the problem at hand.

Isaac Harnack interned at RTP Company at Winona, Minnesota. / Isaac Harnack

At RTP, the global compounder, I showed my technical knowledge and skills that I gained at Stout. Out of the five interns at the company, I had the most hands-on knowledge of the processing aspects of plastic. This was highlighted by my ability to run extruders and injection molding machines with little to no training besides the mandatory safe operating training.

This really showed Stout ��. education compared to other schools’ education in terms of the hands-on knowledge that I brought to the table.

Because of my background, training time was shortened and allowed me to be more autonomous more quickly than other interns, to the benefit of my supervisors. I was the intern to five engineers, while the other interns only had one. Getting on my feet quickly and showing that I could handle a large number of tasks and complete them all within their deadlines really showed my skills effectively. Most plastic-related companies use RTP ��. custom-engineered polymer products. The fact that I had an internship with them has opened a lot more doors.

What stands out about your �� experience?

The biggest thing that stands out is the plastics engineering professors: Alex Jordan, Wei Zheng and Adam Kramschuster. They are all extremely knowledgeable and have different backgrounds in testing and analysis in plastic processing techniques.

I feel this is best highlighted in our capstone projects, which are the final experience as a Stout student. Plastics engineering typically has the best-researched and executed capstone projects, whose subjects range from a heavy testing and analysis focus to a processing focus. Each project is unique, and with it comes unique challenges and questions that, as a student, seem impossible for anyone to know anything about. Every time I talked with my professors about any issues I was having with my project, they would have the answers for me, or, once researched, show me how to properly execute the information I found. Their input on my project has been crucial to furthering my understanding of even the most niche topics.

Another standout experience is the community developed by professors and students, as having such a small and specialized major means that from freshman to senior year, all the people you graduate with are there with you every step of the way.

In terms of my favorite lab experiences, I really enjoyed our Injection Molding II class, where we got to work with manufacturing engineering students to design and machine our own injection molds. My partner and I engineered a golf tee for a simulator, and we had great success with molding our parts. Not many students get to have an experience like this, which really makes you stand out to potential employers.

How did your involvement on campus impact your experience?

As the program ambassador for the plastics engineering program, I am the lead lab assistant. My main goal is to keep the lab running and help with advanced research tasks put forth by the professors or help with lab improvements.

Isaac Harnack served as the plastics engineering program student ambassador. / Isaac Harnack

Just recently, we got the green light for four new 3D printers, which I had a major hand in helping acquire.

This was extremely beneficial to experience firsthand, as most companies have a lengthy process for equipment purchasing, and this experience was no different. Research, planning and ensuring we have enough space and resources available to support new equipment are all factors that play a part, and I had to prove that we could handle them.

I have received scholarships from regional plastic processing companies, which helped relieve some of the financial strain that college puts on a person. There are many internal and third-party scholarships available to plastics engineering students, even as freshmen. We are associated with the Society of Plastic Engineers (SPE), which has hundreds of national student scholarships available to any student who applies and meets the requirements.

What challenges did you face in earning your degree and how did you overcome them?

One of the hardest decisions I had to make was to take University Physics 2 over the summer because it did not fit into my class schedule. This is typically a five-credit class, and over a two-month period, you were expected to complete 40 hours a week of homework. On top of this large amount of homework, I was also working full-time, so for two months straight, I would come home from my eight-hour shift and open up homework for another four to six hours.

What are you most proud of as you finish your degree?

I am most proud of the fact that, in terms of my immediate family, I am the only one to have ever gone to an engineering school. On top of this, I have been able to maintain a consistent 3.7 grade-point average and have been placed on the Dean ��. List every semester.

Earning my plastics engineering degree is undoubtedly one of the hardest things that I have done in my life and seeing it through is what makes this whole journey worth it. It gives me great pride that I stuck with this path and saw it through.

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Inspiring Graduate: Easton Sailer, B.S. Computer & Electrical Engineering

goersab — Tue, 23 Dec 2025 16:25:00 +0000

Inspiring Graduate: Easton Sailer, B.S. Computer & Electrical Engineeringgoersab December 23, 2025

Hired before graduation as Hewlett Packard Enterprise electrical hardware engineer

Inspiring Graduate: Easton Sailer (’25)

Hometown: Pound
Degree: B.S. Computer & Electrical Engineering
Minors: Mathematics, Computer Science

Easton Sailer chose �� because it was close to home, for its excellent value and because his dad earned his master ��. degree here. He was also drawn to the university ��. strong computer and electrical engineering program.

“�� emphasizes hands-on learning and practical experience – something I value more than the traditional, theory-focused approach found at other schools,” Sailer said.

Easton Sailer earned his computer and electrical engineering degree from �� on Dec. 20, 2025.

“I aim to make a meaningful impact in my field by leveraging my expertise in both software and hardware to enhance system-level efficiency, enabling the development of larger, more capable systems that operate with lower power consumption,” he said.

He completed internships with nVent and Hewlett Packard Enterprises – two companies in the data center and high-performance computing sectors. “These experiences allowed me to apply my classroom learning to real-world engineering challenges, while contributing to meaningful projects in my field,” he said.

Sailer earned his CEE degree and minors in mathematics and computer science and crossed the commencement stage on Dec. 20 as one of 527 �� graduates. He was hired before graduation as an electrical hardware engineer at Hewlett Packard Enterprise in Chippewa Falls.

Easton Sailer was hired before graduation by Hewlett Packard Enterprise in Chippewa Falls.

He plans to work in the industry for three to five years before returning to school to pursue a master ��. degree in computer and electrical engineering.

“Gaining real-world experience first will allow me to solidify my interests and make a more informed decision about my area of specialization. Currently, I’m especially interested in data centers and high-performance computing and the opportunities they offer for innovation,” he said.

How has �� prepared you to work in your field?

�� has prepared me to work in my field by combining theoretical knowledge with hands-on lab experience, giving me a strong foundation in both understanding concepts and applying them in practical settings.

My favorite experience was in the Controls and Instrumentation Lab, a class where I learned to program PLCs and HMIs – skills that are widely used in the automation industry and directly relevant to real-world engineering applications.

I completed two internships that further strengthened my practical experience. At nVent, in Anoka, Minnesota, I was a controls/electrical engineering intern, working on high-density liquid cooling units for data center servers and performing pre-production testing to ensure units functioned correctly before mass production.

Computer, electrical engineering students help nVent with product development, testing

Sailer, Pettit gain experience in high density liquid cooling systems for data centers worldwide

At Hewlett Packard Enterprise, I tested power components for future systems, developed evaluation plans for a new coolant distribution method for supercomputers and created programs to visualize signal integrity data.

What stands out about your �� experience?

What stands out most about my �� experience is the strong emphasis on hands-on lab work that complements theoretical learning, allowing me to apply concepts in practical settings.

I also greatly appreciate the professors, who genuinely care about the success of their students and are always willing to provide guidance. Additionally, the program ��. focus on internships ensures students gain real-world experience, which has been invaluable in preparing me for my career.

How did your campus involvement impact your experience?

I was involved in the IEEE (the Institute of Electrical and Electronics Engineers) student chapter for all four years of my studies. As a freshman, I participated as a general member, attending workshops to learn more about electrical engineering and explore different areas within the field. During my sophomore year, I was elected as the digital media coordinator, where I created advertisements for on-campus signage and managed the club ��. social media accounts to promote events and workshops.

In my junior year, I was elected president of the chapter, which allowed me to lead workshops, run board meetings, and collaborate with other officers to organize industry partner presentations and career development activities.

Easton Sailer completed internships with nVent and HPE.

My involvement in IEEE significantly enhanced my college experience by helping me build leadership, communication, and technical skills, while connecting with peers and professionals in the industry.

What challenges did you face in earning your degree and how did you overcome them?

Throughout my bachelor ��. degree, I faced several challenges that ultimately helped shape me into a stronger engineer and student. Finding my first internship was especially difficult because, while I had hands-on experience as a maintenance technician at an injection molding factory, I lacked substantial engineering experience outside of the classroom. After months of persistence and continuous improvement of my résumé and interview skills, I finally secured my first engineering-related internship at nVent.

Another major challenge was our yearlong capstone project with VibeTech, a company developing vibration-based rehabilitation machines for nursing homes. Their openness to any possible solution meant our team had to carefully narrow down the project ��. scope to something realistic for two semesters, which taught us the importance of defining requirements early. We also had to develop strong team coordination and time-management skills to keep the project moving.

As the system architect, I was responsible for outlining how all components would integrate, identifying bottlenecks before they occurred, and ensuring the system ��. overall feasibility. These skills challenged me but ultimately made me a better engineer.

Easton Sailer completing an Iron Man Marathon. / Easton Sailer

What are you most proud of as you finish your degree?

Looking back, I am extremely proud of myself for finishing this program. If you had asked me in high school what I would be doing four years later, I would have guessed welding or electrical work. Instead, I am grateful for the opportunities I’ve been given and for the people who encouraged me to pursue engineering, allowing me to grow far beyond what I once thought possible.

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Cool solution: Faculty-student research will help Madison company ship charcuterie, cheese boards coast to coast

giffeyt — Wed, 17 Dec 2025 14:00:00 +0000

Cool solution: Faculty-student research will help Madison company ship charcuterie, cheese boards coast to coastgiffeyt December 17, 2025

Packaging professor and student identify sustainable insulation option

Tom Giffey

Faculty-student research conducted this fall in University of Wisconsin-Stout packaging labs is poised to help a Wisconsin business deliver its tasty but temperature-sensitive goods coast to coast.

Associate Professor Xiaojing “Kate” Liu of �� . packaging program worked with Madison-based Tricky Foods to test the insulating abilities of two eco-friendly packaging options – one made of cornstarch, the other of recycled paper. The goal: To determine the best way to keep the cheese, meat and other perishables on the company ��. charcuterie boards fresh while in transit.

Therese Merkel, owner of Tricky Foods, worked closely with Liu for months and is confident that the research-backed expertise that she ��. received – and the custom-made packing materials she ordered based on that expertise – will help her small business break into the long-distance delivery market.

“Kate is the only reason I’m able to launch this thing so quickly,” Merkel said in an interview from her Madison office. “She has been the backbone of the entire project.”

Tricky Foods owner Therese Merkel, left, and Assistant Professor Kate Liu collaborate in ��'s packaging lab. / Submitted photo

Research will aid business expansion

Merkel started Tricky Foods in her home kitchen during the midst of the COVID-19 pandemic in 2020. Thanks to her charcuterie boards filled with sliced meats, Wisconsin cheeses, fresh and dried fruits, honey, jams, nuts, and more, the business grew rapidly, and now Merkel has a storefront and 12 employees. But her ability to continue to scale up the business collided with her inability to figure out how to safely ship her goods long distances, despite customers’ requests.

“We’ve had people asking us to ship since 2020. I thought, ‘Oh, I’ll work on it when it slows down,’ and I never got around to it,” she explained.

The route around her business roadblock began when she joined a business accelerator program operated by StartingBlock, a nonprofit regional startup hub and coworking space in Madison.

“Because Therese ��. products are perishable and have a very clear aesthetic, it was clear that she needed to work with packaging experts,” said Scott Mosley, CEO of StartingBlock. “As the state ��. only polytechnic and the only school to have a dedicated packaging program, it was natural to recommend that Therese contact ��.”

Merkel reached out to �� . Office of Corporate Relations & Economic Engagement, which works to connect university resources to business, industry and community stakeholders. Seth Hudson, �� . executive director for corporate relations and economic engagement, put her in touch with Liu.

Corporate Relations & Economic Engagement

��'s Corporate Relations & Economic Engagement is your go-to organization for connecting business and community with our extensive resources.

A sample charcuterie board prepared by Tricky Foods. / Submitted photo

Before partnering with Liu at ��, Merkel explained, “Nobody wanted to work with me because I’m too small at this point. I didn’t have a huge budget to pay someone to help me design something.” However, Liu was willing to collaborate, connecting frequently through video calls to ask questions and show packaging samples. Ultimately, she invited Merkel to visit �� to examine prototypes firsthand, which she did in September.

Once they settled on the optimal packaging – 1.5-inch-thick biodegradable foam insulation, which dissolves in water, wrapped in recyclable plastic and accompanied by 64- to 80-ounce cold gels – Liu helped Merkel identify vendors who could custom-make what she needed.

“I enjoyed it a lot,” Liu said of the collaboration. “(It was) especially satisfying to see the solution carried out and help Tricky Foods’ business.”

Liu said she is confident that the packaging solution will meet Merkel ��. needs, and she added that part of the research results will be published in a peer-reviewed article and presented at an international packaging conference in 2026.

Merkel expects to begin test-shipping products using the new packaging this Christmas season, and she ��. optimistic about the results and the impact on her business. “Next year will definitely be our biggest year ever,” she said.

The efficacy of sustainable packing materials, including cornstarch and recycled paper options (center), were tested at ��.

Impactful undergraduate research

�� is one of only a few schools in the United States, and the only school in the Universities of Wisconsin, that offers a B.S. in packaging program.

Liu ��. lab assistant for the research is Claire Le, a sophomore packaging major from Phu Quoc City, Vietnam. Le said she didn’t expect to be doing such impactful research so early in her college career. “It ��. been challenging, but in the best way,” she said. “I’ve learned a lot about experimental design, budgeting, troubleshooting and presenting results professionally.”

Le said the most interesting part of the project was learning how different kinds of insulating materials behaved in cold-chain conditions. “Testing cornstarch versus fiber liners and tracking how long they keep food under 40°F feels meaningful because we’re working on something that can genuinely impact food safety,” she said.

These packaging options are also more environmentally friendly, replacing products made of polystyrene foam. Repeated lab tests found that cornstarch liners, when combined with cold packs, could keep 5-pound charcuterie boards properly cooled for 48 hours. When sealed correctly, the packages maintain the necessary temperature despite vibrations during transit, which were simulated in the lab with a vibration table that jostled the packages for hours at a time.

“I hope this research gives (Tricky Foods) clear, data-driven recommendations on which insulation material is more reliable for keeping food safe during transport,” Le said. “My goal is for the results to help them make stronger packaging decisions, reduce spoilage and improve their cold-chain performance.”

Merkel called �� a “hidden treasure” because of the expert assistance it can give to businesses like hers.

“For an entrepreneur who ��. new in the e-commerce game, (��) is the difference between me being able to launch this and not,” she said. “Without Kate, I wouldn’t have been able to. I’m just beyond grateful.”

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Packaging professor and student identify sustainable insulation option for small business Tricky Foods owner Therese Merkel and Assistant Professor Kate Liu

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Hero Caption: �� Assistant Professor Kate Liu, left, and her lab assistant, sophomore Claire Le, pose with materials in the packaging lab.

Xiaojing (Kate) Liu

Full Name: Xiaojing "Kate" Liu

Job Title: Associate Professor

Include in Directory: Yes

College: College of Science, Technology, Engineering, Mathematics & Management

Department: Engineering & Technology Department

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B.S. Packaging

Curriculum Vitae: Kate Liu CV (196.61 KB)

Education:

Degree: Ph.D. Mechanical Engineering

University: Wuhan University of Technology

Degree: M.S. Mechanical Engineering

University: Wuhan University of Technology

Degree: B.S. Mechanical Engineering

University: Wuhan University of Technology

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SMART Scholarship recipient guaranteed employment upon graduation

goersab — Mon, 17 Nov 2025 15:02:19 +0000

SMART Scholarship recipient guaranteed employment upon graduation goersab November 17, 2025

Benningfield, mechanical engineering senior, honored to ‘protect our country’ as federal employee

Abbey Goers

�� mechanical engineering senior Heidi Benningfield received more than tuition and an internship through the U.S. military ��. SMART Scholarship program: After graduation, she ��. guaranteed a job with the U.S. Army Space and Missile Defense Command in Huntsville, Alabama.

The Science, Mathematics, and Research for Transformation (SMART) Scholarship-for-Service Program through the Department of War, previously known as the Department of Defense, covers Benningfield ��. full tuition and provides her with an annual stipend for room and board. She recently completed a three-month paid internship as a SMART Scholar Engineer with the U.S. Army Space and Missile Defense Command.

“I have a great respect for our military. To protect our country is an honor,” Benningfield said. “I knew I didn’t want to serve in the military, but I can serve in a different way as a federal DoW employee. Our mission is to support the war-fighter. In that way, I can make an impact to help protect our country.”

Benningfield, of Mokane, Missouri, will graduate in May 2026 and is guaranteed employment with the DoW. Her job will be at the Army ��. Redstone Arsenal Space and Missile Defense Technology Center in Huntsville. She hopes to earn her master ��. degree and carry out a career in defense systems.

The SMART scholarship program is a combined educational and workforce development opportunity for STEM students. The program ��. mission is to attract, recruit, develop, and retain top STEM talent for impactful civilian careers in the DoW, advancing national security and technical superiority through merit-based scholarships for service.

Supporting Space and Missile Defense Command divisions

What interests Benningfield most about engineering is how broad a field it is. “From design to 3D modeling, manufacturing and automation, to system design or sales, the positions are very broad – mechanical engineers do all of that. You can do and be so many things,” she said.

“I’m the type of person who likes to have her hands in every cookie jar. It ��. challenging. Nothing is easy or straightforward. But seeing something go from an idea to an actual implemented system is rewarding,” she added.

Defense systems also require all types of engineers, she said, from knowing the parameters of a project to understanding missile geometry for speed and velocity, or target accuracy and radar detection.

At the Space and Missile Defense Command, Benningfield interned in the Concepts and Analysis Lab, with a cohort of eight SMART scholarship recipients and full-time engineers.

She supported the Test Division and the Weapons & Protective Technologies Division. Her projects included building and integrating the systems and working on a test asset – the Finite Element Analysis, or FEA.

She also supported work on a two-stage light gas gun, testing scale models of missiles. “Much of my skills with the different tools we used came from different lab experiences at Stout,” she said.

With her full-time employment upon graduation, Benningfield will support those divisions for two years. After that, if she chooses to remain at the DoW, she may stay with her preferred division.

In summer 2024, Benningfield was a science undergraduate laboratory intern with the National Renewable Energy Laboratory in Golden, Colorado. She also worked on a project with Sierra Space in Madison, an aerospace and space technology company, machining a combustion chamber component.

Benningfield is a mechanical engineering tutor and has served as a lab assistant at �� . Machine Shop, assisting her peers with projects. “I like the hands-on work in the Machine Shop. Most engineers don’t know how to operate machines. The professors and lab assistants are always willing to help and take their own time to help. The professors want you to succeed,” she said.

She chose �� because it is the only NCAA Division III university that has both a mechanical engineering degree and a gymnastics team. She was on the team for two years and served as a student assistant coach for a year.

“I chose Stout because it felt like home. I felt like I could fit in here,” Benningfield said. “I like the small class sizes and the fact that you can meet one-on-one with professors. I’m grateful for my mentors here and the opportunities and polytechnic experiences Stout gave me.”

��'s Robert F. Cervenka School of Engineering is home to five ABET-accredited programs that also include computer and electrical engineering, engineering technology and plastics engineering, as well as a sixth bachelor ��. program in packaging. A master ��. in manufacturing engineering is available on campus or online.

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�� mechanical engineering senior honored to ‘protect our country’ as federal employee

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�� mechanical engineering senior honored to ‘protect our country’ as federal employee Heidi Benningfield

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B.S. Mechanical Engineering

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�� . packaging program ranks among top 10 in national listings for its polytechnic approach

�� Online engineering, education, management programs ranked among best by U.S. News & World Report