Scott R. Johnston, Ph.D.BACKGROUND

EDUCATION2005 Ph.D., Mechanical Engineering University of Washington Seattle, WA

Advisors: Dr. R. Anderson and Associate Professor D. Storti. Thesis: Initial stage sintering model of 316L stainless steel with application

to three dimensionally printed (3DP™) components.1998 M.S., Mechanical Engineering University of Missouri

Columbia, MO Advisors: Associate Professor Y. Lin. Thesis: Dynamic modeling of helical spring with non-constant pitch.

1995 M.S., Mathematics Kansas State University Manhattan, KS Advisors: Associate Professor A. Bennett Thesis: Solving differential equations using lie groups and their geometric

representations.1993 B.S., Mathematics University of Missouri

Columbia, MO Minor: Philosophy

INDUSTRIAL EMPLOYMENT HISTORY2007-Pres. Research Scientist The Boeing Company St. Louis, MO

Successfully secured funding for internal research projects valued over $4M. Projects selected based upon proposed work scopes to meet internal customer needs and continued accumulated successful technological advancements.

Authored five (5) externally funded project proposals efforts which has resulted in winning an excess of $2.3M of externally funded contract research and development work for Boeing.

Visiting scientist at the Direct Manufacturing Research Center (DMRC) in Paderborn, Germany for two months. Consulted and guided academic chairs and researchers by directing research efforts toward robust manufacturing techniques related to Additive Manufacturing technologies.

Principle Investigator on Direct Write Electronics project. Designed, analyzed and tested experimental machine for deposition of electrically conductive material for proprietary applications. (8+ years)

Principle Investigator: Additive Manufacturing (AM) Design Methodologies. Authored corporate wide AM Design Guidelines illustrating how to design components using AM (2 years).

Principle Investigator on the collaborative ATKINS Project: Low Carbon Manufacturing through Loughborough University. Nine UK based companies involved in analyzing the carbon foot-print of traditional and Additive Manufacturing techniques. (2 years)

Principle Investigator on Renault Formula 1 technical partnership for collaborative efforts on Direct Digital Manufacturing techniques (1 year).

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Scott R. Johnston, Ph.D. Served as a panelist expert for Boeing on advanced manufacturing for BP

Castrol’s Mutative Manufacturing Workshop. The workshop involved the vision of manufacturing in the year 2020.

2006-2008 Research Consultant Innovative Technology Analysts, LLCSeattle, WA

Provided mathematical modeling services of optical system to predict spatial exposure surface for new thin film manufacturing process.

1999-2001 Instrumentation Engineer Emerson Process Management, (PC&E)St. Louis, MO

Led $400K Coors brewery yeast drying facility instrumentation upgrade. Co-authored a proposal for instrumentation on a new Coors brew line resulting

in excess of $10M of consulting work for Emerson. Selected and purchased instrumentation for Monsanto DSIDA process plant

design. 1998-1999 Quality/Process Engineer DaimlerChrysler Fenton, MO

Confirmed minivan assembly process for chassis, engine, tires drive train, and trim lines.

Verified that assembly components met design specifications and quality requirements.

1995-1996 Actuary/Math Analyst National Crop Insurance Services Overland Park, KS

Responsibilities included mathematical analysis of agricultural issues relating to policy coverage of the Standard Reinsurance Agreement between insurances companies and the government.

ACADEMIC EMPLOYMENT HISTORY2007-Pres. Affiliate Professor University of Washington Dept. of Mech. Engineering

Actively advised and guided graduate student on masters research to develop production process of making PZT particles. Research resulted in one publication and three related patents.

2007 Auxiliary Faculty University of Washington Dept. of Mech. Engineering

Taught senior level course in Winter and Spring quarters in mechanical engineering, mechanical vibrations, manufacturing techniques, and non-traditional manufacturing.

2005-2006 Postdoctoral Fellow Georgia Institute of TechnologySystems Realization Lab

Invented a selective curing process using a UV masked projection system for a biomedical application (patent pending). Co-authored a $50K VentureLab proposal to commercialize UV masked projection fabrication technology resulting in startup company, AlpZhi, Inc. AlpZhi launched in 2009 and has been successful with multiple employees.

Advanced NSF funded unit cell truss analysis project by proving that unit cell interaction affects resulting load induced strain values. Experimental analysis was used with comparison to truss analysis FEA program for structural design.

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Scott R. Johnston, Ph.D. Worked integrally with multiple graduate students on MS and PhD programs.

▫ Rebuilt AM equipment and aided PhD graduate student on 3DP metal oxide AM process development. This dissertation won best research dissertation at the Solid Freeform Fabrication (SFF) in 2009.

▫ Advised undergraduate students in senior design project related to unit truss analysis.

▫ Worked with PhD graduate student to enhance and refine micro-SLA process to increase robustness of process.

▫ Consulted with MS student on print head design creating an adjustable design for experimental drop on demand system for high viscosity materials.

2003-2005 Research Assistant University of Washington Dept. of Mech. Engineering

Developed a dimensional model of initial stage sintering for 316L stainless steel with specific applications to three dimensional printing.

2001-2003 Research Graduate II Concurrent Technologies CorporationBremerton, WA

Performed research with senior level CTC employees for all aspects of the Office of Naval Research’s (ONR) Electronically Based Manufacturing using 3DP™ Metalworking’s transition from rapid prototyping to rapid manufacturing.

2003-2005 Instructor University of Washington Dept. of Mech. Engineering

Taught ME 480 CAD/CAM/CAE Technologies & Rapid Prototyping. Instruction in different types of rapid prototyping (RP) machines; ZCorp Three Dimensional Printer, Stratasys FDM, CNC desktop mill, surface scanner, mold making, mold design, and geometric modeling. (3 Quarters)

2002-2003 Lab. Teaching Assistant University of Washington Dept. of Mech. Engineering

ME 480 CAD/CAM/CAE Technologies & Rapid Prototyping. Maintained all equipment for the computational design laboratory which included a mechanical overhaul of a ZCorp three-dimensional printer and set-up of a new laboratory facility. (2 Quarters)

1999 Adjunct Instructor St. Louis CC – Meramec Dept. of Mathematics

MATH 160 College Algebra. Sole instructor for an eight week summer course that covered sixteen weeks of instructional material. (Summer Semester)

1995-1997 Graduate Instructor Sole instructor and responsible for all aspects of teaching mathematics course. College Algebra University of Missouri (3 Semesters) Dept. of

Mathematics Business Calculus Kansas State University (1 Semester) Dept. of Mathematics

1993-2002 Teaching Assistant Calculus I University of Washington (1 Quarter) Dept. of Mathematics

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Scott R. Johnston, Ph.D. Engineering Dynamics University of Washington (3 Quarters) Dept. of Mech.

Engineering Mathematical Modeling University of Missouri (1 Semester) Dept. of Mech.

Engineering Mathematic Courses Kansas State University (4 Semesters)Dept. of

Mathematics

ADDITIONAL PROFESSIONAL CREDENTIALS 2008-Present Department of Defense (DoD) SECRET Security ClearanceAug. 1997 Mathematical Instructor Training Workshop

University of Missouri Participated in a two week instructional training session on using technology in

a teaching environment in Mathematics. The session provided teaching ideas and methods for including calculators, computer programming, and user interface mathematical computer programs (i.e. Mathematica, Matlab, Excel, etc.) in a teaching environment. Coordinated and taught several sessions using expertise in Mathematica and Excel.

Aug. 1993 Mathematics Teaching Assistant Training Kansas State University

Participated in a week training session describing essential skills for teaching mathematics. Sessions included information on lesson plan creation, blackboard management, exam and homework grading, exam writing, and instructor student interaction skills.

TECHNICAL SKILLSProgramming Language Capabilities

Mathematica, Matlab, LaTeX, SAS, and Pascal.Software Proficiency and Experience

Windows OS, MSOffice, ABAQUS, ANSYS, NASTRAN, Unix Network, Java, and SolidWorks.

Additive Manufacturing Processes ZCorp and ProMetal Three-Dimensional Printing (3DP™) machines, Optomec

Aerosol Jet direct write system, Dimension Fused Deposition Machine (FDM), CNC milling, and 3D Systems Stereolithography Apparatus (SLA).

Equipment Operation Fanuc Handling Tool Operation & Programming Certificate, manual and CNC

Milling machine, Instron load frame, Scanning Electron Microscope (SEM), Thermal Dilatometer, Thermo-Gravimetric and Differential Thermal Analyzers (TGA/DTA), and Programmable Coordinate Measuring Machine (CMM).

SCHOLARLY ACTIVITY

FUNDED RESEARCH PROGRAMS1. Title: Thermoformed Direct Write Electronics (Current)

Sponsor: Air Force Research Laboratory (AFRL)Role: Principle Investigator / Program Manager

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Scott R. Johnston, Ph.D.Duration: November 2015 – May 2017Funding Amount: Proprietary

2. Title: Integrated Direct Write Electronics ($704K)Sponsor: Air Force Research Laboratory (AFRL) via Universal Technology Corporation (UTC)Role: Principle Investigator / Program ManagerDuration: November 2013 – February 2015Funding Amount: $704K

3. Title: Direct Write Electronic SystemsSponsor: Air Force Research Laboratory (AFRL) via Universal Technology Corporation (UTC)Role: Principle Investigator / Program ManagerDuration: September 2010 – September 2011Funding Amount: $380K

4. Title: Solder Free ElectronicsSponsor: Air Force Research Laboratory (AFRL) via Optomec, Inc.Role: Principle Investigator / Program ManagerDuration: September 2008 – March 2010Funding Amount: $415K

5. Title: Un-manned Mini UAVSponsor: Air Force Research Laboratory (AFRL)Role: Direct Digital Manufacturing Program Capture LeadDuration: January 2009 – September 2009Funding Amount: $210K

AWARDS2016 Boeing Pride Award – Completion of CRAD project three months early within

budget.2015 Boeing Cash Award – Winning two externally funded projects within a year.2015 Boeing Pride Award – Outstanding project execution and support of

proprietary production meeting all project deadlines and deliverables.2014 Boeing Pride Award – Exemplary maturation of manufacturing technology for

proprietary production. 2012 Boeing Pride Award – Opportunities for New Engineers (ONE) project. Expose

new engineers to direct write coating technologies.2007 Finalist, American Association for the Advancement of Science (AAAS), Science

& Technology Placement offer: Department of Homeland Security (DHS), Science & Technology Directorate, Geophysics/Infrastructure

Selection process involved extensive interview process by government panelists represented by: DARPA, DoD, FBI, DHS, and US State Dept.

2006 Best Paper - Transaction of North American Manufacturing Research Institute of SME, Vol. 34.

PATENTS

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Scott R. Johnston, Ph.D.1. Multi-functional chromatic applique for monitoring of thermal events on a surface

(2016) (Pending)2. Direct Write of Chromatic NDE Probes for tailored and multi-purpose witness

surfaces (2016) (Pending)3. Non-Contact electrical signal transmission to aircraft components utilizing

integrated direct-write electronic fabrication (2015) (Pending)4. Process for fabricating bonded thermoformed circuitry onto additive

manufactured (AM) non-planar mold structure (2015) (Pending)5. Dual process Atomizer for Aerosol Jet deposition  (2013) (Pending)6. Dissipation of electronic charge from substrates (Patent No: 8,717,734)7. Method and System of Fabricating PZT Nano-particle Ink Based Piezoelectric

Sensor (Patent No: 8,614,724)8. Method and System for Distributed Network of Nano-particle Ink Based

Piezoelectric Sensors For Structural Health Monitoring (Patent No: 8,766,511)9. Method, Apparatus and Material Mixture for Direct Digital Manufacturing of Fiber

Reinforced Parts (2010) (Patent Application No: 20130056672)10.In-process orientation of particles used in direct-write inks to control electrical

characteristics of an electrical component being fabricated (Patent No: 8,529,987)11.In-process orientation of particles used in direct-write inks to control electrical

characteristics (Patent No: 8,800,479 ) 12.Method for Making Ophthalmic Devices Using Single Mold Stereolithography

(2007) (Patent Application No: 20090250828)

PUBLICATIONS

ARCHIVAL JOURNAL PUBLICATIONS1. S. Johnston, R. Anderson, and D. Storti, “Sintering Strain of 316L Stainless Steel

Parts Fabricated by Three-Dimensionally Printing,” Transaction of North American Manufacturing Research Institute of SME, Vol. 34, 2006. Awarded Best Paper

PEER REVIEWED NON JOURNAL PUBLICATIONS1. H.V. Wang, S.R. Johnston, and D.W. Rosen, “Design of a graded cellular structure

for an acetabular hip replacement component,” Proceedings of the 2006 Solid Freeform Fabrication Symposium, Austin, TX., August 2006.

2. S. Johnston, R. Anderson, and D. Storti, “Non-isothermal initial stage sintering model with application to 316L stainless steel,” Proceedings of the 2005 Solid Freeform Fabrication Symposium, Austin, TX. (Accepted without revision.)

3. S. Johnston, D. Frame, R. Anderson, and D. Storti, “Strain Analysis of Initial Stage Sintering of 316L SS 3DP™ Components,” Proceedings of the 2004 Solid Freeform Fabrication Symposium, Austin, TX (Accepted without revision.)

4. Johnston, R. Anderson, and D. Storti, “Particle Size Influence upon Sintered Induced Strains within 3DP™ Stainless Steel Components,” Proceedings of the 2003 Solid Freeform Fabrication Symposium, Austin, TX. (Accepted without revision.)

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Scott R. Johnston, Ph.D.NON JOURNAL PUBLICATIONS1. S. Johnston, M. Reed, H. Wang, and D.W. Rosen, “Analysis of Mesostructure Unit

Cells Comprised of Octet-truss Structures,” Proceedings of the 2006 Solid Freeform Fabrication Symposium, Austin, TX.

2. D.W. Rosen, S. Johnston, M. Reed, and H. Wang, “Design of General Lattice Structures for Lightweight and Compliance Applications,” NSF Design, Service, and Manufacturing Grantees and Research Conference, St. Louis, MO, July 25-27, 2006.

3. D.W. Rosen, S. Johnston, M. Reed, and H. Wang, “Synthesis Methods for Structural and Compliant Mesostructured Parts,” Rapid Manufacturing Conference, Loughborough University, UK, July 5-6, 2006.

4. S. Johnston and R. Anderson, “Finite Element Thermal Analysis of Three Dimensionally Printed Metal Matrix Composites, Proceedings of the 2002 Solid Freeform Fabrication Symposium, Austin, TX.

5. Y. Lin and S. Johnston, “Dynamic Modeling and Simulation of Variable Pitch Helical Springs,” Spring Industry Technical Symposium 1999.

INVITED PRESENTATIONSDec. 2015

“Chopped Fiber/Polymer Additive Manufacturing,”“Integrated Direct Write Electronics,” Defense Manufacturing Conference 2015, Phoenix, AZ.

May 2015

“Direct Write Electronics in Aerospace Environments,” Pacific Northwest Consortium for the Advanced Manufacturing of Smart Goods, Portland, OR.

Nov. 2014 “Direct Write in Aerospace Environments,” IDTechEx, San Jose, CA.

Jan. 2014

“Engineering Imagination and Additive Manufacturing,” Villanova University, PA.

Sept. 2013

“Engineering Imagination and Additive Manufacturing,” Virginia Tech, Blacksburg, VA.

Nov. 2011

Panelist: Creation of Electronic Components & Circuits Using Layered Additive Direct-Write Technologies,” Defense Manufacturing Conference 2011, Anaheim, CA

Aug. 2011

“Additive Manufacturing, What it means to Boeing,” RapidTech National Teacher Training Workshop, 2011, Irvine, CA

May 2011

Keynote Speaker: “Transitioning from Prototyping to Manufacturing,” Rapid Tech DE, Erfurt, Germany

Feb. 2011

Panelist: Panel Expert for BP Castrol Mutative Manufacturing Workshop, Luton, England.

Aug. 2010

“Additive Manufacturing (AM), What is that?” RapidTech National Teacher Training Workshop 2010, UC Irvine.

May 2010

SME Bright Minds Mentor Program, RAPID 2010, Additive Manufacturing in Aerospace Applications.

“Increasing the Technology Readiness Level of Additive Manufacturing Processes” Nov.

2009 May

2009

Department of Mechanical Engineering, University of Washington-SeattleDepartment of Mechanical Engineering, Villanova UniversityDepartment of Mechanical Engineering, University of Liverpool, United Kingdom

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Scott R. Johnston, Ph.D. Oct.

2008April 2008

Additive Manufacturing and its capabilities. Internal Boeing presentation to weight reduction team.

June 2006

Hands On NanoBio Fluidic MEMS Workshop Instructor, “Stereolithography and Rapid Prototyping,” Georgia Institute of Technology, Atlanta, GA, www.dlpe.gatech.edu/nanobio

May 2006

“Sintering Strain of 316L Stainless Steel Parts Fabricated by Three-Dimensionally Printing”, 34th North American Manufacturing Research Conference, Milwaukee, WI.(Best Paper Presentation)

July 2004

Project Review for 3DP™ Thermal Post processing Analysis, ExtrudeHone Corporation, Bremerton, WA.

Feb. 2004

“Initial Stage Sintering Analysis of 3-Dimensionally Printed Components,” University of Leeds, UK.

Mar. 2002

Project Review Presentation for Three Dimensional Printing (3DP™) Research, presented to Leo Plonsky, Project Manager for MANTECH, Division of Office for Naval Research (ONR).

CONFERENCE PRESENTATIONSMay 2012

“Direct Write Technology Deposition Testing Overview,” SME RAPID/3D Imaging Conference 2012, Atlanta, GA

May 2012

“Properties of Conductive Traces Produced by Direct Write,” Boeing Technical Excellence Conference (BTEC) 19, 2012, El Segundo, CA

Aug. 2006

“Analysis of Mesostructure Unit Cells Comprised of Octet-truss Structures,” 2006 Solid Freeform Fabrication Symposium, Austin, TX. (Session Chair)

Aug. 2005

“Non-isothermal initial stage sintering model with application to 316L stainless steel,” 2005 Solid Freeform Fabrication Symposium, Austin, TX.

Aug. 2004

“Strain Analysis of Initial Stage Sintering of 316L SS 3DP™ Components,” 2004 Solid Freeform Fabrication Symposium, Austin, TX.

April 2004

“Rapid Prototyping to Rapid Manufacturing,” University of Washington, Department of Mechanical Engineering.

Aug. 2003

“Particle Size Influence upon Sintered Induced Strains within 3DP™ Stainless Steel Components,” 2003 Solid Freeform Fabrication Symposium, Austin, TX.

July 2003

Project Review for 3DP™ Experimentation relating to powder particle size and strain formation, CTC/ExtrudeHone Corp., Bremerton, WA.

Aug. 2002

“Finite Element Thermal Analysis of Three Dimensionally Printed (3DP) Metal Matrix Composites,” 2002 Solid Freeform Fabrication Symposium, Austin, TX, Poster Presentation.

PROFESSIONAL SOCIETY MEMBERSHIP & ACTIVIITES2012-2014 Member of Industrial Advisory Board to the European Support Action for

Standardization in Additive Manufacturing (SASAM)2008-Pres. American Society of Testing and Materials (ASTM)

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Scott R. Johnston, Ph.D. Voting member for Boeing on the F42 Additive Manufacturing Standards

development committee. Wrote ASTM accepted standards in: Terminology, AM Machine coordinate

systems, and Polymer Laser Sintering. Vice Chair – Design Subcommittee (2013-2014) Task Group Co-Chair for Additive Manufacturing Design Guide Development

(2012-Pres.) ANSI Representative to ISO TC 261 for standardization meeting.

2009-Pres. Society of Manufacturing Engineers (SME) Technical review committee member of Military & Aerospace papers for RAPID

2010-Present. Participant in the Bright Minds Mentorship program, 2009-2013. Member of

Bright Minds organizational committee for RAPID 2010-13. 2003-2008 American Society of Mechanical Engineers (ASME)2003-2007 Society of Automotive Engineers (SAE)2006 Habitat for Humanity construction volunteer (Seattle, WA)1993-1996 American Mathematical Society (AMS)

SERVICE

EXTERNAL COLLABORATION2012 – Pres. Chair of Industrial Advisory Board (IAB) for NSF grant RapidTech

working with Saddleback College, CA and University of CA-Irvine. 2004 Self Organizing Systems Group, University of Washington Nils Napp & Dick

Keisberg, Mechanical design and implementation of a self-assembling robotic units.

DEPARTMENTAL SERVICESept. 2004 Coordinator of Teaching Assistant (TA) Training Workshop

University of Washington Organized, coordinated and taught training session for new and current

teaching assistants (TA) for the Department of Mechanical Engineering. The workshop included instruction for day to day activities that are required as a teaching assistant, including: lesson plan preparation, lecture skills, grading techniques, TA-professor and TA-student relationships, and laboratory instructional skills.

COLLEGE SERVICE2005-2006 Sophomore machine design competition judge. Georgia Institute of Technology April 2004 College of Engineering Open House Volunteer Computational Design LaboratoryApril 2002 College of Engineering Open House Volunteer Computational Design Laboratory

UNIVERSITY SERVICE

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Scott R. Johnston, Ph.D.2000-2005 Graduate Professional Student Senate (GPSS), University of Washington

Finance and Budget committee, 2003-2004

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