Yaoyao Fiona Zhao

Follow us on:

Assistant Professor

Ph.D. University of Auckland

M.Eng. University of Auckland

B.Eng. Beijing Institute of Technology

Macdonald Engineering Building, Room 148 Map

External Website

INTRALATTICE Software Website

514.398.2523 [office]

514-398-7365 [Fax]

yaoyao.zhao [at] mcgill.ca (Email)


Research Interests

Primary Research Theme: Design and Manufacturing, Engineering and Design for Sustainability, Manufacturing Informatics
Secondary Research Theme: Bioengineering, Materials and Structures

Facility: Additive Design and Manufacturing Laboratory (ADML)

My research interests are in the general area of design and manufacturing, including the exploration of new design methods, the use of advanced technologies, and the integration of better computer software and metrology tools to improve production. My research program is focused on two central and connected themes: 1) Sustainable Manufacturing; and 2) Additive Manufacturing. The first aims are to develop sustainability analysis methods and material databases, to establish information and process models and metrics, and to analyze end-of-life product reuse/recycling methods. The second aim is to explore and discover applications for new and emerging additive manufacturing technologies, within a sustainable manufacturing perspective. Rising concerns over escalating emissions, resource depletion, and other environmental issues have led to an increased emphasis on the design and manufacturing of environmentally benign products. Additive manufacturing with its unique capabilities has brought great potentials in product design, re-manufacturing, repair and direct manufacturing.

Current Research Projects

New design method and materials for additive manufacturing

New design theory and methodologies to improve products’ sustainability and to fully utilize the capability of additive manufacturing in developing new design prototypes for medical and aerospace applications.

Our team has developed an open-source design software – INTRALATTICE – that specializes at lattice structure design.

Exploring fabrication technique and process control methods for new materials (i.e. biocompatible ceramics, wood, and fibre) that can be used in various additive manufacturing processes.

Environmentally benign manufacturing research

Quantify environmental related impacts generated through manufacturing processes with a focus of assessing sustainability of additive manufacturing processes.

Establish sustainability metrics and database for different types of manufacturing processes with the eventual development of web-based sustainability assessment tools.

Manufacturing informatics for the integration of manufacturing systems

Integrate data and models across manufacturing shop-floors and networks with information modelling languages, protocols, and technologies.

Simulation and optimization of internet-based manufacturing (e-manufacturing) specifically for the support of smart machining and additive manufacturing technologies.

Most Significant Publications

Authored book:

Yaoyao (Fiona) Zhao, Robert Brown, Thomas Kramer, Xun Xu, “Information Modelling for Interoperable Dimensional Metrology”, September 2011, Springer, ISBN 978-1-4471-2166-4.

Book chapters:

Yaoyao Fiona Zhao, Nicolas Perry, Hery Andriankaja, “A Manufacturing Informatics Framework for Manufacturing Sustainability Assessment”, Re-engineering Manufacturing for Sustainability, pp 475-480, 2013.

Journal papers:

Yunlong Tang, Yaoyao Fiona Zhao, “BESO based design method for lattice structure fabricated by Additive Manufacturing”, Computer-aided Design, Special Issue on Geometric and Physical Modeling for Additive Manufacturing, accepted, 2015.

Sheng Yang, Yaoyao Fiona Zhao, “Additive Manufacturing Enabled Design Theory and Methodology: A Critical Review”, International Journal of Advanced Manufacturing Technologies, accepted, 2015.

Han Chen, Yaoyao Fiona Zhao, “Process Parameters Optimization for Improving Surface Quality and Manufacturing Accuracy of Binder Jetting Additive Manufacturing Process”, Rapid Prototyping, accepted, 2015.

Yunlong Tang, Yaoyao Fiona Zhao, “A survey of the design methods for additive manufacturing to improve functional performance”, Rapid Prototyping, accepted, 2015.

Sheng Yang, Yaoyao Fiona Zhao, “A new part consolidation method to embrace the design freedom of additive manufacturing”, Journal of Manufacturing Processes, accepted, 2015.

Yunlong Tang, Yuhaowei Zhou, Thibault Hoff, Martin Garon, Yaoyao Fiona Zhao, “Mechanical properties of 316 Stainless-steel lattice structure produced by Binder Jetting Process”, Materials Science and Technology, Special Issue of Additive Manufacturing of Metals for Aerospace Applications, accepted, 2015.

Xin Xu, Simon Meteyer, Nicolas Perry, Yaoyao Fiona Zhao, “Energy consumption model of Binder-Jetting Additive Manufacturing Processes”, Special Issue on Energy-Aware Manufacturing Operations, International Journal of Production Research, published online, 16 July 2014.

Hardwick, Yaoyao Fiona Zhao, F. M. Proctor, et al., “A Roadmap for STEP-NC Enabled Interoperable Manufacturing”, International Journal of Advanced Manufacturing Technology, Vol. 68, Issue 5-8, pp 1023-1037, 2013.

Yaoyao Fiona Zhao, X. Xu, "Integrating Machining and Inspection", International Journal of Computer Aided Engineering and Technology, Vol. 4, No. 1, pp 1-31, 2012.

Yaoyao Fiona Zhao, X. Xu, Tom Kramer, Fred Proctor, John Horst, “Dimensional Metrology Interoperability and Standardization in Manufacturing Systems”, Computer Standards & Interfaces, 33, pp 541-555, 2011.

Yaoyao Fiona Zhao, X. Xu, “Enabling Cognitive Manufacturing through Automated On-Machine Measurement Planning and Feedback”, Special Issue of Cognitive Factory, Advanced Engineering Informatics, 24, pp 269-284, 2010.


MECH 360 Principles of Manufacturing 3 Credits
    Offered in the:
  • Fall
  • Winter
  • Summer

MECH 500 Sel Topics in Mechanical Eng 3 Credits
    Offered in the:
  • Fall
  • Winter
  • Summer

For Information Regarding Research Position Openings under Professor Zhao