What if casting and forging operations could predict defects before they occur, repair tooling in hours instead of weeks, and continuously improve with every part produced? This presentation highlights how the University of Illinois is integrating additive manufacturing and AI to modernize legacy processes, unlocking faster lead times, reduced costs, and greater design freedom without compromising reliability.
From AI-driven inspection and digital twins to advanced repair and hybrid manufacturing approaches, these capabilities enable foundries and forging operations to extend tool life, improve quality, and respond to demand with unprecedented speed. The result is a step-change in productivity and competitiveness, positioning U.S. casting and forging to lead in the next generation of manufacturing.
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Presenter
Federico Sciammarella
Executive Director, Illinois Manufacturing Institute
Dr. Federico Sciammarella is the Executive Director of the Illinois Manufacturing Institute (IMI) at The Grainger College of Engineering at the University of Illinois Urbana-Champaign, where he leads efforts to advance AI-enabled manufacturing and next-generation intelligent machine systems. His work focuses on uniting industry, academia, and government to accelerate the adoption of smart, connected manufacturing technologies and strengthen U.S. industrial competitiveness.
Previously, Dr. Sciammarella served as Chief Technology Officer and President at MxD, the U.S. national center for digital manufacturing and cybersecurity, where he helped define and deploy large-scale Industry 4.0 initiatives. He also held academic leadership roles at Northern Illinois University, directing advanced manufacturing research and leading major federally funded programs in additive manufacturing process modeling and control. Earlier in his career, at Council for Scientific and Industrial Research in South Africa, he led laser materials processing initiatives that translated into commercial technologies. Across his career, Dr. Sciammarella has consistently bridged cutting-edge research with real-world manufacturing impact at scale.
Jeremy Smith
Technical Specialist, IMEC
Jeremy Smith is a lean manufacturing and continuous improvement specialist at IMEC with more than 10 years of experience in complex automotive electronics manufacturing. He partners with Illinois manufacturers to improve operational performance, strengthen production systems, and implement sustainable continuous improvement initiatives that drive measurable results.
Jeremy brings global manufacturing experience, having worked with cross-functional teams across multiple countries to align strategy, improve productivity, and build high-performing operations. His value stream–focused approach helps manufacturers identify opportunities, eliminate waste, and implement structured systems that improve efficiency, quality, and supply chain performance.
At IMEC, Jeremy helps organizations apply lean tools, data analysis, and structured problem-solving methods to maximize return on investment and build cultures of continuous improvement.
Expertise
Lean Transformation & Continuous Improvement
Value Stream Mapping & Production Flow Optimization
Strategy Deployment & Productivity Improvement
Visual Management & Shop Floor Systems
Supply Chain & Supplier Performance Improvement
Six Sigma Problem Solving
Certifications & Credentials
Six Sigma Black Belt
B.S., Materials Science & Engineering – University of Illinois
Impact Snapshot
Delivered 16M in cost savings through structured continuous improvement initiatives
Strengthened operational performance through value stream optimization
Improved productivity, quality, and production flow using lean methodologies
Supported sustainable performance improvements through data-driven decision making
