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UC engineer applying generative AI to smart manufacturing

Manish Raj Aryal is earning his PhD in mechanical engineering

headshot of Lindsey Osterfeld By Lindsey Osterfeld
8 minute read March 31, 2025

In 2021, Manish Raj Aryal arrived from Nepal to pursue his master's degree in mechanical engineering at the University of Cincinnati and has continued his research as a PhD student. Today, he is working on revolutionizing manufacturing systems through generative AI, leveraging AI systems to develop manufacturing assistant chatbots. He was recently named Graduate Student Engineer of the Month by UC's College of Engineering and Applied Science. 

Why did you choose UC? What drew you here?

Manish Raj Aryal smiles at the camera. He is wearing a tan coat and white shirt.

Manish Raj Aryal came to UC from Nepal for his master's degree and continued his research as a PhD student. Photo/Provided

The University of Cincinnati stood out to me because of its strong emphasis on innovation, research, and industry collaboration, especially in the fields of AI-driven manufacturing and computational design. I was drawn to UC's world-class facilities, particularly within the Department of Mechanical and Materials Engineering, where cutting-edge research is continuously pushing the boundaries of smart manufacturing. In addition, the opportunity to work with Dr. Sam Anand, a renowned expert in AI-assisted manufacturing at the Smart Manufacturing Lab played a pivotal role in my decision. 

Beyond the academic and research excellence, UC fosters a culture of collaboration — both within CEAS and through partnerships with industry leaders, providing opportunities to bridge cutting-edge research with real-world applications. Looking back, I realize that joining UC has been one of the best decisions I've made. The supportive research community, state-of-the-art resources, and opportunities for interdisciplinary collaboration have genuinely shaped my academic and professional growth. I'm proud to be a Bearcat!

Why did you choose your field of study?

Growing up in the 2000s, I was a massive fan of Iron Man (like most of the people in my age group), and Tony Stark was a mechanical engineer. I told my mom that I wanted to follow a similar path and become a mechanical engineer where I could design, build, and innovate. My passion for designing and building started at a young age, and I still vividly remember the excitement of receiving LEGOs as a gift, surpassing anything else. The love for designing and building something from scratch stayed with me as I grew older. I was equally drawn to computers and tools to develop, design, and manufacture things. In my undergraduate studies, I worked to develop assistive prosthetic hands for children, aiming to create accessible solutions for people in need. 

As I delved deeper into assistive design, the emergence of AI in design and manufacturing fascinated me. Long story short, I realized the potential of AI-assisted design to revolutionize manufacturing processes. Thus, I am pursuing a doctoral degree in mechanical engineering, where I plan to integrate AI and generative design to develop intelligent manufacturing processes and systems. 

Briefly describe your research work. What problems do you hope to solve?

Manish Raj Aryal stands at a podium and gives a presentation. A large board with information is behind him.

Manish Raj Aryal works on the development of intelligent automation systems. Photo/Provided

My research focuses on applying artificial intelligence and generative design to enhance manufacturing and product development. At the core, I explore how AI-driven design models — such as Generative Adversarial Networks (GANs) and Large Language Models (LLM – for example, ChatGPT) can assist in automating design generation, visualization, and optimization of the manufacturing process. 

A key area of my research is to develop AI-powered design tools that can generate complex 3D geometries for manufacturing components, such as heat exchangers and medical implants. I integrate computational modeling tools, computer vision techniques, and generative design algorithms to improve geometric complexity. These techniques help optimize key design parameters (such as weight distribution, structural integrity, and heat transfer efficiency), enabling the design and development of lighter, stronger, and more efficient manufacturing components. 

My research also explores AI-driven object recognition and large language model-assisted decision-making to enhance intelligent manufacturing processes and automation. I work to develop a machine learning algorithm (that operates on synthetic 'fake' images) to identify and classify manufacturing components accurately, enhancing worker training and maintenance processes. In addition, I specialize in the development of AI-powered chatbots that interpret design parameters and assist troubleshooting engineers in real-time decision-making. These AI assistant-design chatbots engage in dynamic, knowledge-driven, and continuous learning processes to provide more accurate context-aware support. Overall, by pushing the boundaries of AI-assistive manufacturing, I aim to contribute towards the development of intelligent automation systems for driving the next era of innovation and efficiency. 

What are some of the most impactful experiences during your time at UC?

Throughout my time at UC, there have been many moments where I felt my research truly made a difference. One of them was during the deployment of the CranialRebuild software. CranialRebuild is a computation software that we developed in collaboration with the UC Department of Neurosurgery that automatically generates cranial implants for patients with skull injuries. The software could automatically generate cranial implants in just three minutes — a process that would typically take a skilled professional several days to complete. It not only dramatically reduced time and effort but also allowed implants to be produced with minimal expertise, allowing advanced medical solutions to be more accessible and efficient. 

We worked with a group of neurosurgeons from Ukraine to deploy the software in the hospital to generate quick cranial flaps for injured soldiers. The software was deployed in war-torn areas and provided a critical solution for neurosurgeons treating wounded soldiers. The knowledge of having my research translated from the lab into a real-world scenario was incredibly rewarding. It reaffirmed that all the hard and long hours in the lab were truly worth it, showing that innovation can drive meaningful, real-world change. 

In addition, I have had the opportunity to contribute to multiple high-impact research projects in collaboration with industry leaders at companies including Raytheon Technologies, Eaton Corporation, and Siemens Inc. My research efforts have resulted in several peer-reviewed publications, posters, conference papers, and patents at top mechanical engineering conferences such as the North American Manufacturing Research Conferences. I have also served as a peer-reviewer for prestigious journals (such as IJIDeM, PIAM, and JBSME) and contributed to the academic society. 

My journey here at UC has been enriched by receiving numerous UC scholarships, such as Professor Kirti "Karman" Ghia Endowed Graduate Student Scholarship, the Youngblood Richard Hagedorn Scholarship, and the Fenton D. Snodgrass Memorial Scholarship. In addition, I was honored to be selected as an IRiS Graduate Research Fellow for the 2023-24 academic year, an interdisciplinary experience that allows me to broaden my horizons. These experiences have played a pivotal role in my academic and professional growth, and I am proud of my time at UC. 

Do you have any other hobbies or involvements you'd like to share?

Outside of my research, I have a passion for exploration, fitness, and sports. I am an avid runner and am gearing up to run the Flying Pig half marathon later this summer. I enjoy playing sports, and have a tremendous appreciation for experiencing new food, wine, and culture. I love discovering new cuisines, unique flavors, and traditions from around the world. I'm always looking to experience something new, whether it's travel or a culinary adventure. As they say — work hard, play harder! 

Additionally, I am very grateful for the opportunities UC has provided me to grow as a researcher and innovator. I look forward to continuing my journey in AI-driven engineering and contributing to the future of smart manufacturing. 

Featured image at top: Manish Raj Aryal is applying generative AI to smart manufacturing. Photo/Unsplash

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