AMSM Lab
Western University · Mechanical & Materials Engineering

Additive Manufacturing for Sustainable Materials Laboratory

Low-Carbon · Renewable · Circular
AMSM Lab research vision: multiscale engineering of sustainable materials through material extrusion additive manufacturing

About Our Research

The Additive Manufacturing for Sustainable Materials (AMSM) Laboratory focuses on advancing sustainable materials through additive manufacturing. Our research explores how additive manufacturing processes can be used not only to shape materials, but also to engineer their internal structures and properties across multiple scales during fabrication.

We develop advanced additive manufacturing technologies and processing strategies, integrating feedstock engineering, process control, and materials characterization to establish processing–structure–performance relationships.

Our current research focuses on three sustainable material systems: low-carbon functional materials, renewable-fiber composites, and recycled polymers, with applications in carbon capture, lightweight structures, and circular manufacturing.

Principal Investigator

Chao Xu, Principal Investigator of AMSM Lab

Chao Xu, Ph.D.

Incoming Assistant Professor
Department of Mechanical & Materials Engineering
Western University · January 2027

Dr. Xu develops advanced material extrusion technologies, including pore-forming, rotational, and field-assisted direct ink writing for multiscale materials engineering.

Research

Multiscale Engineering of Sustainable Materials through Material Extrusion Additive Manufacturing.

Current Research

Conceptual close-up of a 3D-printed porous adsorbent from the homepage research illustration

Low-Carbon Functional Materials

Architectural Scale

We investigate additively manufactured low-carbon geopolymer–zeolite adsorbents for CO₂ capture. Using direct ink writing (DIW), particularly rotational direct ink writing (RDIW), we aim to engineer pore orientation and connectivity within printed filaments while maintaining larger flow channels. Our research explores how pore architecture influences gas transport, dynamic CO₂ adsorption, and mechanical integrity.

Conceptual illustration of magnetic-field-assisted printing and oriented renewable fibers

Renewable-Fiber Composites

Microstructural Scale

We develop magnetic-field-assisted DIW strategies to control the orientation and deformation of flexible renewable fibers during printing. By understanding the interplay between magnetic fields, extrusion flow, and fiber behavior, we aim to engineer location-specific reinforcement and improve composite performance under multidirectional loading.

Conceptual illustration of fused granulate fabrication and polymer chain extension

Recycled Polymers

Molecular Scale

We investigate in-situ polymer chain repair during fused granulate fabrication (FGF) of recycled thermoplastics, including recycled polyethylene terephthalate (PET). By integrating chain extension into the final melt-extrusion stage, we aim to restore polymer processability and mechanical performance while reducing unnecessary additional melt-processing steps.

Selected Research Contributions

Pore-Forming Direct Ink Writing

We developed pore-forming DIW to fabricate hierarchical porous structures by introducing sacrificial particles to create tunable intra-filament pores independently of designed structural pores. This approach has been demonstrated in 3D-printed metallic bone implants.

Representative Publications

Xu C., Additive Manufacturing (2022)

Xu C., Additive Manufacturing (2023)

Pore-forming direct ink writing of Ti6Al4V metallic ink showing solvent evaporation, binder removal, and sintering

Magnetic-Field-Assisted DIW

We developed magnetic-field-assisted DIW to spatially program magnetic particle orientation and magnetic moment distributions during printing. This method enables multimodal actuation in 3D-printed soft structures.

Representative Publication

Xu C., Additive Manufacturing (2025)

Magnetic-field-assisted direct ink writing: field-controlled orientation and programmed bending, folding, and rolling

Rotational Direct Ink Writing

We developed RDIW to organize materials within printed filaments through controlled nozzle rotation, enabling programmable helical and multimaterial architectures. This approach has been demonstrated in bioinspired structural materials.

Representative Publication

Ren L., Chemical Engineering Journal (2024)

Programmable Functional Materials

We developed DIW-based strategies that combine magnetic programming, energy storage, and responsive polymer materials to control actuation and shape locking. These strategies enable programmable motion and adaptive soft robots.

Representative Publications

Xu C., Advanced Science (2025)

Han Y., Advanced Composites and Hybrid Materials (2026)

People

Principal Investigator

Chao Xu, Principal Investigator of AMSM Lab

Chao Xu, Ph.D.

Incoming Assistant Professor
Department of Mechanical & Materials Engineering
Western University
Starting January 2027

chao.xu.me@gmail.com

Google Scholar ↗

Biography

Dr. Chao Xu is an incoming Assistant Professor in the Department of Mechanical & Materials Engineering at Western University, starting in January 2027.

His research focuses on advanced additive manufacturing and materials engineering, with particular expertise in material extrusion (MEX) technologies. He has developed customized additive manufacturing systems and processing strategies, including pore-forming direct ink writing, rotational direct ink writing, and field-assisted printing, to control material composition, architecture, microstructure, and properties across multiple scales.

His research has enabled advances in additively manufactured functional materials and structures, with applications in biomedical implants, programmable soft robotics, smart materials, and multimaterial systems. His broader research experience also includes metal additive manufacturing and functional metallic structures.

At Western University, he will establish the Additive Manufacturing for Sustainable Materials (AMSM) Laboratory, focusing on the multiscale engineering of low-carbon, renewable, and recycled materials through advanced additive manufacturing.

Education

2018Ph.D. in Mechanical Engineering
Polytechnique Montréal, Canada
2014B.Eng. in Mechanical Engineering
Jilin University, China

Academic Appointments

2027–Incoming Assistant Professor
Western University, Canada
2019–2026Professor / Associate Professor / Assistant Professor
Jilin University, China
2025Visiting Scholar
University of Oxford, UK
2019Postdoctoral Fellow
McGill University, Canada

Selected Honors & Awards

2025CAST Youth Talent Award
China Association for Science and Technology
2024Tang Aoqing Distinguished Scholar
Jilin University

Publications

Journal publications in additive manufacturing, materials engineering, and functional structures.

Research Highlights

Selected publications showcasing material extrusion technologies, programmable materials, and multiscale structures.

Advanced Healthcare Materials, volume 13 issue 10, 2024 cover featuring DIW Ti6Al4V bone scaffolds
Journal Cover Highlight

Advanced Healthcare Materials (2024), Volume 13, Issue 10.

Cover artwork featuring direct ink writing of Ti6Al4V bone scaffolds.

View published cover ↗

† Equal contribution (co-first author)    * Corresponding author. Authorship symbols are shown where confirmed from the publication or an institutional author list.

All Journal Publications

33 peer-reviewed journal articles (2017–2026), organized by publication year.

Jump to: 2026 2025 2024 2023 2022 2021 2020 2019 2018 2017

2026

2025

2024

2023

2022

2021

2020

2019

2018

2017

† Equal contribution (co-first author)    * Corresponding author. Symbols are shown only where a published author note or institutional publication list identifies the role.

Opportunities

Prospective PhD Students

The AMSM Lab welcomes prospective PhD students with backgrounds in mechanical engineering, materials science and engineering, chemical engineering, polymer engineering, or related disciplines. Research opportunities focus on low-carbon functional materials, renewable-fiber composites, and recycled polymers through material extrusion (MEX) additive manufacturing.

Experience in one or more of the following areas is particularly welcome:

Applicants do not need experience in every area. Candidates with strong research potential and relevant technical backgrounds are encouraged to apply.

How to Apply

Please email your CV, academic transcripts, and a brief description of your research interests and relevant experience to chao.xu.me@gmail.com.

Required email subject: Prospective PhD Student – AMSM Lab

Formal admission is subject to Western University's graduate admission requirements. Available positions and funding will be discussed with prospective candidates.

Contact

Chao Xu, Ph.D.
Department of Mechanical & Materials Engineering
Spencer Engineering Building
Western University
London, Ontario, Canada N6A 5B9

Email: chao.xu.me@gmail.com