Rensselaer CATS' Dr. Stephen Rock Promoted to Senior Research Scientist

Steve RockSteve Rock

Rensselaer CATS' Dr. Stephen Rock has been promoted to Senior Research Scientist.  Steve joined Rensselaer's Flexible Manufacturing Center (FMC) in 2003 and the CATS in 2005 when the FMC and the CATS merged.   Steve has led or contributed to numerous projects developing advances in manufacturing technologies and systems and energy management, and is currently co-lead of the CATS fuel cell manufacturing program with Prof. Dan Walczyk.
Steve Rock’s bio:
Dr. Stephen Rock earned a B.S. in Electrical Engineering from Union College in 1989, an M.S. in Computer & Systems Engineering from Rensselaer Polytechnic Institute in 1991, and a Ph.D. in Computer & Systems Engineering from Rensselaer in 2000.
Steve leads projects and conducts research on information-driven manufacturing process development often involving advanced technologies such as laser systems, industrial robotics, and ultrasonic processing.  Much of Steve’s recent work has focused manufacturing process improvements for fuel cell membrane electrode assembly production.  Results of this work have been commercialized and fielded on manufacturing lines in Germany and the United States.  Steve has participated on the team that proposed, won, and developed several courses for the NSF IGERT in the Engineering, Science, and Entrepreneurship of Fuel Cells, and he is participating on the multi-year DOE project entitled Adaptive Process Controls and Ultrasonics for High Temperature PEM MEA Manufacture.  He recently served as a Subject Matter Expert on the ONR-sponsored Fuel Cell Manhattan Project.
In addition to information-driven manufacturing process development, Steve has research interests in CAD/CAM, industrial automation and robotics, rapid prototyping and rapid tooling, laser-based sensor systems, and energy management algorithms and systems.  His prior research has included development of a CAD/CAM interface for Solid Freeform Fabrication processes that comprised work on 3D model validity checking, automated repair, topology based slicing, and creation of an improved file format for storing facet model data.  Steve invented and patented powder-based Rapid Prototyping (RP) process, and he applied finite element modeling techniques and powder sintering models to perform shape optimization and correct for process-induced geometric distortions inherent in this process.  This work was funded by a DOE Integrated Manufacturing and Processing pre-doctoral fellowship.  Steve has worked for IBM applying digital logic emulation technologies (electrical rapid prototyping), and he has consulted for several companies, including Philips and DTM Corp. (Desk Top Manufacturing), on a range of issues from process software development to industrial automation and control.