Workforce development a key priority for Purdue Applied Research Institute hypersonics manufacturing facility
WEST LAFAYETTE, Ind. — A study conducted by the National Defense Industrial Association’s Emerging Technologies Institute indicates that the United States faces a critical shortage of technically skilled workers throughout the hypersonics industry. The Hypersonics Advanced Manufacturing Technology Center (HAMTC) has dedicated part of its mission to help build up the hypersonics workforce by training talented students and staff on real-world projects that impact U.S. defense priorities.
HAMTC is the flagship hypersonics manufacturing facility for the Purdue Applied Research Institute (PARI). It is one of the only centers in the nation that enables the design, manufacturing, joining and testing of hypersonic systems in one location, thereby enabling its workers and trainees to touch every step of the hypersonics supply chain.
“HAMTC, and PARI as a whole, have provided an avenue for rapidly clearing and transitioning talented students to the defense industrial base at a time where it desperately needs them,” said Greg Scofield, director of the PARI Hypersonics Lab, which oversees HAMTC. “We’ve transitioned graduate and undergraduate students with clearances over to our partner companies. That’s a huge win for us.”
Since its inception in December 2022, HAMTC has supported over 20 students, some of whom have been recruited by companies in the defense industry. One such former student, Liam Ward, who researched critical joining technologies for hypersonic boost-glide vehicles, was recruited by a HAMTC industry partner following the completion of his MS in aeronautics and astronautics in May 2024.
“During the collaboration, we got to know each other, and it was essentially a two-year interview because they got to see how I worked that entire time,” Ward said. “My role at HAMTC mirrored the kind of work I’m doing now, and I think it really helped prepare me to work through the uncertainty that is associated with working on cutting-edge technology and tackling challenging projects.”
Ward also noted how HAMTC provides students with valuable experience working with sensitive and controlled information, fostering an understanding of the care and precision required in such environments.
“My two years with HAMTC instilled a deep appreciation for the importance of safeguarding sensitive information while offering hands-on experiences in implementing the necessary protocols for maintaining security in these contexts,” Ward said.
Additionally, HAMTC provides opportunities for seasoned professionals looking to enhance their careers. Gregg Lubas, previously a U.S. Marine Corps field technician and a service technician, is a processing engineer at HAMTC, meaning he manages the production processes, finishes and treats printed parts, and maintains the machinery at the center. Lubas said he has found fulfillment in the role he plays in revolutionizing hypersonics manufacturing.
“You’re always innovating; no two days are ever the same,” Lubas said. “It’s the only place where you can come into the building with a drawing on a napkin and come out with a tested, ready-to-run part. I did a lot of work on the scramjet with machining and heat treatments, and I’m really proud of how that project turned out.”
Because of HAMTC’s variety of capabilities, staff can go beyond their assigned roles and learn new skills across the hypersonics manufacturing supply chain. Lubas, for example, aims to work more on the modeling and simulation of hypersonic components, as this part of the process directly affects the shape and functionality of the parts he ultimately finishes.
“When you 3D-print a component, the material often undergoes warping due to the heat from the laser, which results in your dimensions being off for these parts with really complex geometries,” Lubas said. “So, essentially, I’d like to learn how to use modeling as a way to anticipate that warping and print the part in the correct dimensions from the get-go.”
What ultimately sets HAMTC apart, according to Ward, is its collaborative environment. Under one roof, students, staff and faculty are tackling critical research problems while engaging with multiple industry partners. This convergence of talent, expertise and resources creates a uniquely integrated and impactful setting to advance national security research and technology.
“Workforce development is key in what we’re doing,” Ward said. “There’s a lot of appetite for young engineers who can bring energy and ideas to difficult problems. Continuing to have that pipeline is a real benefit to Purdue, to industry, and to the nation as a whole.”
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Media contact: Lindsey Macdonald, macdonl@purdue.edu