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Holistic Innovation in Additive Manufacturing (HI-AM 2.0)

From process optimization to multi-scale modeling and machine learning, Waterloo researchers receive widespread support to develop technologies of the future

What sets Waterloo apart are our multi-disciplinary approaches to research with deep connections with industry. Thanks to major funding, a group of researchers is set to make a meaningful impact, advancing sustainable innovation and training the next generation of leaders in From process optimization to multi-scale modeling and machine learning, Waterloo researchers receive widespread support to develop technologies of the futurethe additive manufacturing, or 3D printing, sector. 

The Holistic Innovation in Additive Manufacturing (HI-AM 2.0) project will focus on training highly qualified professionals (HQPs) and developing technologies that reduce the environmental footprint of advanced manufacturing. The work builds on the previous HI-AM Network that worked to address the challenges that prevented the industrial adoption of metal AM and equip Canada for the ongoing disruptions in manufacturing as a result of digital technologies and geopolitical contexts. 

The newest project is supported by two grants totaling $10.9 million from the Natural Sciences and Engineering Research Council of Canada (NSERC) and Mitacs, as well as funding from industry partners from sectors such as aerospace, automotive and energy. 

“The announcement of HI-AM 2.0 is a testament to the success of the original project and will continue to accelerate the industrial adoption of metal additive manufacturing in Canada,” says Charmaine Dean, vice-president, Research and International. “Importantly, the project will also train the next generation of HQPs who will ensure that the sector continues to grow and thrive, thus strengthening our economy. HI-AM 2.0 is just the latest example of how Waterloo successfully partners with industry and with other academic institutions to maximize resources and impact.” 

The original HI-AM Network ran from 2017 to 2024 and brought together 19 leading AM experts from several Canadian universities. The network set out to train 78 HQPs at different stages in their academic careers, ultimately exceeding that goal by training more than 140 individuals, who lent their expertise in various industry sectors to drive growth across the country. 

Among them are two PhD students who founded Retinex, a start-up that advances quality assurance for laser AM and welding applications. 

Today, many industries benefit from the HI-AM group’s innovations, including automotive, aerospace, energy, engineering, AM material suppliers, and original equipment manufacturers.   

"As the original network was nearing its conclusion, we received widespread support and encouragement from stakeholders to continue the initiative in some form, which underscored the success of the original program and highlighted the ongoing demand for large-scale collaborative research on disruptive technologies in Canada," says Dr. Ehsan Toyserkani, engineering professor, Canada Research Chair in AM, and director of HI-AM 2.0.

With the strong demand for this network, a total of 17 collaborative projects have been approved under HI-AM 2.0, each designed to tackle challenges hindering the industrial adoption of metal AM. The research covers a broad range of topics, including process optimization for advanced alloys, multi-scale modelling, digital twin modelling, machine learning applications in quality assurance for AM and efforts to scale production through multi-laser and large-envelope processes.

“The role played by our private sector, not-for-profit and government partners in the success of this large-scale initiative cannot be overstated," says Dr. Mihaela Vlasea, associate director of HI-AM 2.0 and associate professor in the Department of Mechanical and Mechatronics Engineering. "Collectively, our partners bring access to high-caliber Canadian talent, as well as diverse levels of experience with additive manufacturing. Through low-risk, high-impact research projects, we can guide businesses in adopting more sustainable technologies from a design, material, performance, and cost perspective.”

HI-AM 2.0 will continue to bring together leading research, academic and industry partners from across the country to develop materials and processes to advance AM. The program will support Canadian businesses and help position the country as a pioneer in the application and development of innovative AM technologies.

The University of Waterloo acknowledges the support from the Natural Sciences and Engineering Research Council of Canada (NSERC) Alliance and the NSERC Alliance-MitacsAccelerate Fund.

For more information on NSERC and Mitacs, visit their websites below:

https://www.nserc-crsng.gc.ca/index_eng.asp

https://www.mitacs.ca

A student-designed electric race car from the University of Waterloo powered its way to a top-place finish at the Formula Hybrid+Electric competition, a premier international student challenge for hybrid and electric vehicles.

The University of Waterloo’s Formula Electric (UWFE) team earned its podium result at the New Hampshire Motor Speedway, competing against 28 other teams from across North America in late April.

Hosted by Dartmouth College, the annual event tested student-built vehicles for speed, handling, endurance and energy efficiency.

With a redesigned electrical system and year-long focus on reliability, the team’s car excelled under pressure, highlighting not only technical performance but also the depth of student collaboration and innovation behind the build.

An alumnus of Waterloo Engineering has been recognized by an industry publication as one of the 100 leading women in the North American automotive industry.

Erin Buchanan (BASc ’98, chemical engineering), general manager of Toyota Motor Manufacturing Canada in Cambridge, made the Automotive News list for 2025 alongside CEOs, engineers, founders, marketers and financiers described as “visionaries, problem-solvers and catalysts for change.”

In a story about the winners, Buchanan credited Waterloo and its co-op program with leading her into the auto industry.

“Through the co-op program, I was able to gain insight into some manufacturing supply chain companies. I spent several co-op terms working for a few automotive suppliers,” she said.

“That gave me insight into how competitive the industry is, how fast-paced the industry is, how quickly models are changing, how integrated the supply chain can be, how important the relationships are between an OEM and their supplier partners.”

Buchanan was one of only 11 Canadian women named to the list, which is announced by the weekly, Detroit-based newspaper every five years.

Faculty of Engineering researchers from the Cybersecurity and Privacy Institute have been awarded over $1.1 million in funding from the National Cybersecurity Consortium (NCC) to advance two cybersecurity projects focused on enhancing digital security in Canada. This funding is part of the Cyber Security Innovation Network (CSIN), a national initiative funded by the Canadian government and led by NCC – a not-for-profit organization co-founded by the University of Waterloo to support cybersecurity research, training, and commercialization.

The NCC’s 2024 Call for Proposals allocated $22.8 million in total to 37 projects aimed at bolstering Canada’s cybersecurity resilience. "A resilient digital landscape is vital to the well-being and security of all Canadians,” said Dr. Charmaine Dean, NCC Board chair and vice-president, Research and International at the University of Waterloo. “This funding announcement is an important step forward in maintaining our country as a leader in cybersecurity.”

Faculty of Engineering projects awarded funding

Two Waterloo Engineering projects, led by faculty members and supported by NCC funding, focus on critical areas in cybersecurity: adaptive defense strategies in autonomous driving systems and training in robotics cybersecurity.

• Adaptive defense strategies for advanced driver-assistance systems (ADAS): A game-theoretic approach
  Lead researchers: Dr. Seyed Majid Zahedi and Dr. Rodolfo Pellizzoni with collaboration from Dr. Mahesh Tripunitara
  Funding awarded: $164,622.50
  This project aims to develop adaptive defense strategies for ADAS by applying game-theoretic models to strengthen real-time response capabilities against AI-driven attacks. The team’s approach focuses on enhancing security protocols by incorporating real-time data to support adaptive policies that counter evolving threats in autonomous driving systems.
   
• CRAFT: Cybersecure robotics and future talent
  Lead researchers: Dr. Sebastian Fischmeister and Dr. Yue Hu
  Funding awarded: $1,000,000
  Addressing the growing need for skilled robotics cybersecurity professionals, CRAFT is a comprehensive training initiative that combines cybersecurity principles with robotics. The program partners with industry leaders, offering hands-on training, offensive and defensive cybersecurity courses, a robotics cyber range, and tabletop exercises to simulate real-world scenarios. “Waterloo is very well positioned in this regard with a large variety of available hardware, a large portion of which is government funded,” said Dr. Hu. “By sharing our resources and educational materials, we aim at increasing the impact of the program overall."

These projects underscore the University of Waterloo’s commitment to advancing cybersecurity and its role in training future talent to secure Canada’s digital landscape.

Go to Cybersecurity and Privacy Institute secures $1.5M in funding for more.

Road vehicles are a significant source of pollution in Canada, accounting for about 145.1 megatonnes of carbon dioxide equivalent in 2016, or about 21 percent of total greenhouse gas emissions.

As a result, municipalities are beginning to consider the environmental costs of vehicle emissions as part of their traffic management practices. The Region of Waterloo in Ontario, for example, looks at fuel consumption and emissions when conducting intersection control studies.

Anechoic chamber is free from noise and electronic interference, leading to new scientific breakthroughs in Waterloo

WATERLOO — The heavy steel door inside Room 1018 of the Engineering 5 building at the University of Waterloo looks more like a bank vault than the entrance to a laboratory.

University of Waterloo students drove away from the first part of a competition to develop a self-driving car with four awards and a fourth place overall finish.

A decade of research at Waterloo Engineering has yielded promising new technology to boost the efficiency of internal combustion engines.

Validated tests in the lab have shown gains of more than 10 per cent for a patented system to open and close engine valves, an innovation that would save money while also reducing greenhouse gas emissions.

Both simple and reliable, the technology could significantly reduce fuel consumption in everything from ocean-going ships to compact cars.

Autonomous tech can slow down vehicle attacks, but won't stop them completely, professor says

The van attack that killed 10 people in north Toronto has some observers asking if there's a high-tech way to prevent similar assaults. But experts say technology won't be enough to stop people from using vehicles as weapons.

In the wake of the Toronto van attack that killed 10 people and injured 14 others on Monday, many are left wondering how a tragedy like this can be prevented from happening again.

Some experts are turning their attention to enhanced vehicle technology, such as automatic braking systems. This involves sensors on a vehicle that can detect a crash, warn the driver and apply brakes if the person behind the wheel does not take action quickly enough.