Dr. Huachao Mao is an Assistant Professor at the School of Engineering Technology, Purdue University. His research interests mainly focus on precision Additive Manufacturing processes (optics, functional polymer, microfluidics, and structural composite) and advanced computing for manufacturing (digital twin, topology optimization, process optimization, AI+ML for manufacturing, and smart manufacturing). 

Dr. Mao directs Purdue’s Additive & Intelligent Manufacturing Lab, where he advances precision additive manufacturing that pairs nanoscale patterning with complex 3-D geometries. Dr. Mao’s research has significantly advanced the field of precision additive manufacturing (AM) and its applications in optics, microfluidics, and biomedical technologies. He has made a series of contributions to bridge the nanoscale precision with additive manufacturing, including adaptive slicing, mask image optimization, curved layer deposition, defocused projection, index-matching materials, and precision spin coating. 

Dr. Mao’s impact is reflected in three best-paper awards (ASME MSEC 2021; NAMRC 2016, 2018), nine U.S. patents, and invited talks at major conferences. He reviews for top journals (Nature, Adv. Materials, Science Robotics) and federal agencies, and serves on editorial boards for Micromachines and Digital Manufacturing Technology. He leads NSF-funded projects on 3-D-printed optical AI processors and robotic e-skin. Purdue has honored him with its 2024 Departmental Achievement and 2025 Outstanding Faculty in Discovery at Purdue Polytechnic.