Bio
Dr. Thomas Feldhausen is a research staff member in the Manufacturing Science Division at Oak Ridge National Laboratory and a Joint Faculty Research Assistant Professor in the Department of Aerospace and Mechanical Engineering at the University of Texas at El Paso. He received his bachelor’s and master’s degrees in mechanical engineering from Kansas State University, focusing on engineering curriculum development, and earned his Ph.D. from the Georgia Institute of Technology in hybrid (additive and subtractive) manufacturing.
Dr. Feldhausen began his career at Honeywell Federal Manufacturing and Technologies in Kansas City, where he developed multi-axis direct ink-write additive manufacturing techniques. He joined ORNL in 2019, where he has served as the technical lead for hybrid manufacturing and has significantly advanced the integration of additive, subtractive, and forming processes for industrial applications. His research has supported solutions in component repair, tooling, advanced energy systems, aerospace, automotive, and national security applications through work conducted at the Department of Energy’s Manufacturing Demonstration Facility.
Dr. Feldhausen’s contributions have been recognized through numerous honors, including the Society of Manufacturing Engineers Outstanding Young Manufacturing Engineer Award, SME’s “30 Under 30” distinction, the National Nuclear Security Administration Defense Programs Award of Excellence, and multiple R&D 100 Awards. He was also selected to participate in the National Academy of Engineering’s Grainger Foundation U.S. Frontiers of Engineering Symposium. He currently serves as an Associate Editor for Manufacturing Letters and on the ASME Manufacturing Engineering Division’s Technical Committee for Manufacturing Processes.
Currently, Dr. Feldhausen is advancing ORNL’s portfolio of convergent and hybrid manufacturing systems research, developing technologies and materials that enable rapid production, repair, and replacement of critical components for clean energy and defense manufacturing. His recent efforts increasingly focus on expeditionary and distributed manufacturing, applying ORNL’s capabilities to provide agile, resilient production methods in austere or forward-deployed environments.
Awards
- R&D 100 Award 2025 - Future Foundries: A Foundational Research Platform for the Integration of Emerging Systems
- R&D 100 Award 2023 - OpeN-AM: A Platform for Operando Neutron Diffraction Measurements of Additive Manufacturing
National Academy of Engineering
- Selected attendee of The Grainger Foundation U.S. Frontiers of Engineering. September 2022. Held in Seattle, WA.
- Session organizer for 2023 EU-US Frontiers of Engineering Program. “Future Challenges in Additive Manufacturing”. Murray Hill, NJ.
The Society of Manufacturing Engineers
- The Society of Manufacturing Engineers Outstanding Young Manufacturing Engineer Award, 2022.
- The Society of Manufacturing Engineers, 30 under 30, 2022
National Nuclear Security Administration
- National Nuclear Security Administration Defense Program Award of Excellence, 2018.
Trademarks and Patents
S. Kim, A. A. Hassen, J. M. Lindahl, L. J. Love, V. Kunc, and T. Feldhausen, “System and method for simulation-assisted additive manufacturing,” U.S. Patent 11,794,415, Oct. 24, 2023.
R. R. Pillai, S. Nag, and T. Feldhausen, “U.S. Patent 12,186,809,” U.S. Patent 12,186,809, 2025.
S. Kim, A. A. Hassen, J. M. Lindahl, L. J. Love, V. Kunc, and T. Feldhausen, “System and method for simulation-assisted additive manufacturing,” WO Patent Application WO 2022/183080 A1, Sept. 2022.
D. Wilson, J. McNay, A. McGrath, T. Reckers, T. Feldhausen, K. Saleeby, S. Hattori, S. Koike, and M. Onji, “Additive manufacturing machine,” U.S. Patent Application US 2022/0274202 A1, Sept. 2022.
J. Karandikar, K. Saleeby, S. Smith, T. Feldhausen, and T. Schmitz, “Stability boundary and optimal stable parameter identification in machining,” U.S. Patent Application US 2022/0161381 A1, May 2022.