Julian
Hansell

This internship is funded through the DOE Science Undergraduate Laboratory Internship (SULI) program, where I work on a variety of projects related to advanced manufacturing and automation. Working with my mentor Alex Roschli I have found ways to apply my skills in 3D modeling, problem solving, and system design to improve the capabilites and impact of manufacturing technologies. One of the coolest parts of working at the MDF is the opportunity to work on a wide range of projects across different manufacturing technologies, from Binder Jetting to hybrid additive and subtractive systems. Some of my current projects include:

• Leading the design of a custom 5-axis FFF platform to replicate tool-path movement of an Okuma Hybrid CNC.
• Preparing a novel automated drone manufacturing system for a live conference demonstration.
• Engineering components for an innovative Continuous Thermal Forming system.
• Expanding throughput of the MDF small scale polymer lab while maintaining effective operations.

Along with showcasing my technical skills, the SULI program is also working to bolster my soft skills. Networking events, writing workshops, and presentation competitions are all ways that I am being pushed to increase my interpersonal and communication abilities.

I am conducting research on soft robotics under the guidance of my advisor Robert MacCurdy. My primary research objective is to increase the performance of Pneumatic Network actuators by integrating rigid endoskeletons. This is done in a single fast manufacturing step using a J750 PolyJet printer. I aim to reduce the manufacturing barrier for this type of actuator while increasing its capabilities, to promote implementation of this useful and versitile mechanism.

• Designing soft robotic PneuNet actuators with rigid endoskeletons to improve performance.
• Optimized conductive and elastic TPE print profiles for 3D-printable capacitive skins on robotic arms.
• Selected to present PneuNet research at NCUR 2026.
• Collaborating with graduate researchers on open-source soft robotics design methodologies.

So far I have presented my research at NCUR 2026 and am hoping to publish in a IEEE journal in the fall.

The Idea Forge is a makerspace on CU Boulder's campus that aids students as they machine parts for their projects. Students most frequently use the manual lathes and mills in the shop. As a Student Shop Smith, I teach students on how to safely and effectively use the equipment, and assist them in machining their parts. I also teach students the fundamentals of M.I.G. welding through several workshops each week. My main responibilities include:

• Train and assist students with manual machining and welding.
• Ensure safe operation and maintenance of fabrication equipment.
• Work with students to develop detailed and useful engineering drawings for manufacturability.

I've really enjoyed this position because it has been a great space for me to enhance my manufacturing capabilities while helping other students accomplish thier passions.

Supported live event production across the school district, providing technical AV support for concerts, shows, and sporting events. As my first job this position was a great opportunity for me to develop my teamwork and problem-solving skills in a fast-paced, high-pressure environment. After my freshman year our faculty direction left requiring me to take on more responsibility and Leadership. Our team continued to succeed in providing high quality AV support for our events, and my capabiliteis expanded with advanced effect programing and more in depth system setup.

• Worked well in a team setting, providing support and guidance.
• Performed service and system maintenance as directed.
• Programmed and operated audio-visual equipment to support seamless live events.
• Worked over 60 events including concerts, dance shows, and sporting events.

This job was also my introduction into technical theater as I eventualy became president of our High School's technical theater department.

I competed in First Tech Challenge (FTC) for four seasons, leading the Hardware subteam for three and leaading the Drive team for the last year. FTC is what sparked my passion for engineering and provided the foundation for my technical skills. As Hardware Lead, I was responsible for designing and fabricating the mechanical systems of our robot, as well as leading the build season process. As Drive Team Lead, I was responsible for leading the strategy and execution of our robot during competitions. Our team was known for our impressive software and automation, a lot of my time and effort went into desinging smart systems that the software team could reliably control.

• Designed and fabricated complex robotic mechanisms for 5 robots using CAD and additive manufacturing.
• Won 30+ awards including World Championship Winning Alliance (2022, 2025), World Championship Think Award (2025).
• Logged 600+ hours of design time in Onshape greatly inmproving my proficiency in 3D modeling.

As I think back on my time in FTC I definelty the highlights, Award ceremonies and victories. But what makes me feel the most nostalgic are the late night CAD sessions and the feeling of success after finally solving a sneaky problem that has plagued us for days.