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    Responding to Ukraine’s “ocean of suffering”

    Within 72 hours of the first Russian missiles striking Kyiv, Ukraine, in February 2022, Ian Miller SM ’19 boarded a flight for Poland.

    Later, he’d say he felt motivated by Kyiv’s “tragic ocean of suffering” and Ukrainian President Zelensky’s pleas for help. But he arrived with little notion of what to do.

    As he’d anticipated, his hotel in Rzeszów turned out to be a hub for aid workers and journalists. Miller was on his laptop, using the lobby Wi-Fi to work remotely as an MIT Energy Initiative (MITEI) project manager, when he overheard a reporter interviewing a Finnish man about his efforts to get bulletproof vests and helmets to the front lines.

    Miller soon found himself loading supplies onto trains that had brought huge numbers of refugees — mostly women, children, and the elderly — to the station in Rzeszów. The trains ran back at night, their empty seats filled with medical supplies, generators, and baby food, their lights dimmed to reduce the chances of attack.

    In April 2022, Miller and volunteers from a half-dozen countries planned and drove a convoy of trucks packed with tourniquets, bandages, and bulletproof vests across the border, arriving at the site of the Bucha massacre soon after the Russians retreated.

    Miller peered into a mass grave. “They were still excavating it, and those weren’t soldiers, you know?” he says. “I try to avoid looking at things like that too often, because it doesn’t help us save lives to be horrified all the time.” He downplays any potential danger to himself, telling his family he’s safer where he is than in parts of the United States.

    Soon after his first trip across the border, Miller convinced his former MIT roommate, Evan Platt SM ’20, to come help. “Just for a week,” he told Platt.

    Inspired by energy

    Miller and Platt met in 2008 in Washington, where Platt was interning at the White House and Miller was about to start his senior year at Georgetown University.

    Miller majored in government, but his interest in energy policy and technology grew during the years after graduation he spent teaching science to primary and secondary school students in New York, where he’d grown up; in Boston; and in Kampala, Uganda. “Some of the most fun, inspiring, engaging lessons and modules I did with the kids were focused on energy,” he recalls.

    While pursuing an MIT master of science in chemical engineering from 2016 to 2018, he started researching photovoltaics and wind power. He held leadership positions with the MIT Energy Conference and the MIT Energy Club.

    After joining MITEI, Miller worked on electric vehicles (EVs), EV charging patterns, and other applications. He became project manager and research specialist for the Sustainable Energy System Analysis Modeling Environment (SESAME), which models the levels of greenhouse gas emissions from multiple energy sectors in future scenarios.

    Miller and Platt reconnected and shared an apartment for three years. Platt studied systems design and management through a joint MIT School of Engineering and Sloan School of Management program, then stayed on to work for the MIT Technology Licensing Office.

    Platt left MIT to pursue other interests in 2020. The next time the two would see each other would be in Poland.

    “It’s not easy living and working in an active combat zone,” Platt says. “There is nobody on Earth I would rather be navigating this environment with than Ian.”

    Navigating the last mile

    In Rzeszów and Ukraine, Miller and U.S. Air Force veteran Mark Lindquist oversaw fulfillment for the new team. With the help of Google Translate, their phones lit up with encrypted texts to and from Polish customs agents and Ukrainian warehouse operators.

    Platt and two Ukrainian team members took the lead on a needs analysis of what was most in demand at the front. Another team member led procurement. Their efforts crystallized in the creation of Zero Line, a tax-exempt nonprofit that works closely with the Ukrainian government at the front line (a.k.a. “the zero line”).

    With Platt on board, “we got more rigorous and quantitative in terms of lives-saved-per-dollar,” Miller says. A hundred dollars buys four tourniquets. A thousand dollars adds crude steel armor to a Jeep. Two thousand dollars provides a small observation drone or a satellite phone, equipment that locates Russian artillery and detects Russian attacks.

    “Russian artillery shells are the No. 1 killer of Ukrainians, causing around 80 percent of casualties,” he says. “Tourniquets save people injured by Russian shells, vehicles help evacuate them, and communications equipment prevents deadly injuries from occurring in the first place.”

    Miller’s skills in transportation and power system modeling, developed at MITEI under Principal Research Scientist Emre Gençer, helped the team transport more than 150 used vehicles — Nissan Pathfinders and vans for moving civilians away from the front, Ford pickups for transporting anti-missile defense systems — and hundreds of batteries, generators, drones, bulletproof vests, and helmets to the front through nightmarish logistical bottlenecks.

    Typically, supplies from the United States, Asia, and elsewhere in Europe move through Gdansk and Warsaw, then proceed via train or vehicle to warehouses in Lviv, around 70 kilometers east of the border. Next is the seven-hour trip to Kyiv or the 12-hour drive to Dnipro (the current southern edge of the safe “green zone”) and the final 200 kilometers to the front. Here, says Miller, drivers with training and protective gear, often members of the Ukrainian military, take vehicles and supplies to front-line end users.

    “From day one, we asked our Ukrainian members and partners for introductions, and we’re constantly looking for more,” Miller says. “When our vehicles reach the front lines, Evan’s team always does interviews about needs, and what’s working, what’s not. What’s saving the most lives.”

    “From my early days with Ian, it’s clear he was always looking for ways to help people. Connections were really important to him,” says MITEI Director Robert C. Armstrong. “When war broke out, he found the call to answer human need irresistible. I think many of us think of doing that, but we get bogged down in the mechanics of everyday life. He just picked up and went.

    “Ian is just a terrific person and a great role model,” Armstrong says.

    Accelerating peace

    From the time Miller arrived in late February through October 2022, he continued working remotely for MITEI. He now works full time as co-director of Zero Line. For the foreseeable future, Miller will remain in Ukraine and Poland.

    He wants to see Ukrainians “follow in the happy, free, prospering footsteps of other ex-Soviet states, like the Baltics,” he says. He’d like to see the supply-chain innovations he and Platt achieved applied to humanitarian crises elsewhere.

    To date, Zero Line has raised more than $5 million in donations and delivered hundreds of tons of high-impact aid. “A key part of our approach has always been to support Ukrainians who excel in saving lives,” Miller says. To that end, the group works with Ukrainian software programmers and military units to create digital maps and processes to replace paper maps and operations “reminiscent of World War II,” Platt says. “Modernizing the intelligence infrastructure to facilitate better military operations is an important part of how a smaller military can beat a larger, more powerful military.”

    The fact that energy underlies so many aspects of the war is never far from Miller’s mind. Russia cut off energy supplies to Europe, then targeted Ukraine’s energy infrastructure. On one hand, he understands that billions of people in developing countries such as India need and deserve affordable energy. On the other hand, he says, oil and gas purchases by those countries are directly funding Russia’s war machine.

    “Everyone wants cheap renewables and we’re getting there, but it’s taking time. Lowering the costs of renewables and energy storage and supporting nascent commercial fusion — that’s a very important focus of MITEI. In the long run, that’ll help us reach a more peaceful world, without a doubt.”

    Work at MITEI and at Zero Line, Miller says, “truly could accelerate peace.” More

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    Greening roofs to boost climate resilience

    When the historic cities of Europe were built hundreds of years ago, there were open green spaces all around them. But today’s city centers can be a 30-minute drive or more to the vast open greenery that earlier Europeans took for granted.

    That’s what the startup Roofscapes is trying to change. The company, founded by three students from MIT’s master of architecture program, is using timber structures to turn the ubiquitous pitched roofs of Paris into accessible green spaces.

    The spaces would provide a way to grow local food, anchor biodiversity, reduce the temperatures of buildings, improve air quality, increase water retention, and give residents a new way to escape the dense urban clusters of modern times.

    “We see this as a way to unlock the possibilities of these buildings,” says Eytan Levi MA ’21, SM ’21, who co-founded the company with Olivier Faber MA ’23 and Tim Cousin MA ’23. “These surfaces weren’t being used otherwise but could actually have a highly positive contribution to the value of the buildings, the environment, and the lives of the people.”

    For the co-founders, Roofscapes is about helping build up climate resilience for the future while improving quality of life in cities now.

    “It was always important to us to work with as little contradictions to our values as possible in terms of environmental and social impact,” Faber says. “For us, Roofscapes is a way to apply some of our academic learnings to the real world in a way that is tactical and impactful, because we’re tapping into this whole issue — pitched roof adaptation — that has been ignored by traditional architecture.”

    Three architects with a vision

    The founders, who grew up in France, met while studying architecture as undergraduates in Switzerland, but after graduating and working at design firms for a few years, they began discussing other ways they could make a difference.

    “We knew we wanted to have an impact on the built environment that was different than what a lot of architectural firms were doing. We were thinking about a startup, but mostly we came to MIT because we knew we’d have a lot of agency to grow our skills and competency in adapting the built environment to the climate and biodiversity crises,” Faber explains.

    Three months after coming to MIT, they applied to the DesignX accelerator to explore ways to make cities greener by using timber structures to build flat, green platforms on the ubiquitous pitched roofs of European cities’ older buildings.

    “In European city centers, two thirds of the roofs are pitched, and there’s no solution to make them accessible and put green surfaces on them,” Cousin says. “Meanwhile, we have all these issues with heat islands and excessive heat in urban centers, among other issues like biodiversity collapse, retention of rain water, lack of green spaces. Green roofs are one of the best ways to address all of these problems.”

    They began making small models of their imagined green roofs and talking with structural engineers around campus. The founders also gained operational knowledge from MIT’s Center for Real Estate, where Levi studied.

    In 2021, they showcased a 170-square-foot model at the Seoul Biennale of Architecture and Urbanism in South Korea. The model showed roofs made from different materials and pitched at different angles, along with versions of Roofscapes’ wooden platforms with gardens and vegetation built on top.

    When Levi graduated, he moved to Paris, where Cousin and Faber are joining him this spring. “We’re starting with Paris because all the roofs there are the same height, and you can really feel the potential when you go up there to help the city adapt,” says Cousin.

    Roofscapes’ big break came last year, when the company won a grant from the City of Paris as part of a program to improve the city’s climate resilience. The grant will go toward Roofscapes’ first project on the roof of a former town hall building in the heart of Paris. The company plans to test the project’s impact on the temperature of the buildings, humidity levels, and the biodiversity it can foster.

    “We were just three architects with a vision, and at MIT it became a company, and now in Paris we’re seeing the reality of deploying this vision,” Cousin says. “This is not something you do with three people. You need everyone in the city on the same side. We’re being advocates, and it’s exciting to be in this position.”

    A grassroots roof movement

    The founders say they hear at least once a week from a building owner or tenant who is excited to become a partner, giving them a list of more than 60 buildings to consider for their systems down the line. Still, they plan to focus on running tests on a few pilot projects in Paris before expanding more quickly using prefabricated structures.

    “It’s great to hear that constant interest,” Levi says. “It’s like we’re on the same team, because they’re potential clients, but they’re also cheering us on in our work. We know from the interest that once we have a streamlined process, we can get a lot of projects at once.”

    Even in just the three years since founding the company, the founders say they’ve seen their work take on a new sense of urgency.

    “We’ve seen a shift in people’s minds since we started three years ago,” Levi says. “Global warming is becoming increasingly graspable, and we’re seeing a greater will from building owners and inhabitants. People are very supportive of the notion that we have a heritage environment, but as the climate changes drastically, our building stock doesn’t work anymore the way it worked in the 19th century. It needs to be adapted, and that’s what we are doing.” More

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    Titanic robots make farming more sustainable

    There’s a lot riding on farmers’ ability to fight weeds, which can strangle crops and destroy yields. To protect crops, farmers have two options: They can spray herbicides that pollute the environment and harm human health, or they can hire more workers.

    Unfortunately, both choices are becoming less tenable. Herbicide resistance is a growing problem in crops around the world, while widespread labor shortages have hit the agricultural sector particularly hard.

    Now the startup FarmWise, co-founded by Sebastien Boyer SM ’16, is giving farmers a third option. The company has developed autonomous weeding robots that use artificial intelligence to cut out weeds while leaving crops untouched.

    The company’s first robot, fittingly called the Titan — picture a large tractor that makes use of a trailer in lieu of a driver’s seat — uses machine vision to distinguish weeds from crops including leafy greens, cauliflower, artichokes, and tomatoes while snipping weeds with sub-inch precision.

    About 15 Titans have been roaming the fields of 30 large farms in California and Arizona for the last few years, providing weeding as a service while being directed by an iPad. Last month, the company unveiled its newest robot, Vulcan, which is more lightweight and pulled by a tractor.

    “We have growing population, and we can’t expand the land or water we have, so we need to drastically increase the efficiency of the farming industry,” Boyer says. “I think AI and data are going to be major players in that journey.”

    Finding a road to impact

    Boyer came to MIT in 2014 and earned masters’ degrees in technology and policy as well as electrical engineering and computer science over the next two years.

    “What stood out is the passion that my classmates had for what they did — the drive and passion people had to change the world,” Boyer says.

    As part of his graduate work, Boyer researched machine learning and machine vision techniques, and he soon began exploring ways to apply those technologies to environmental problems. He received a small amount of funding from MIT Sandbox to further develop the idea.

    “That helped me make the decision to not take a real job,” Boyer recalls.

    Following graduation, he and FarmWise co-founder Thomas Palomares, a graduate of Stanford University whom Boyer met in his home country of France, began going to farmers’ markets, introducing themselves to small farmers and asking for tours of their farms. About one in three farmers were happy to show them around. From there they’d ask for referrals to larger farmers and service providers in the industry.

    “We realized agriculture is a large contributor of both emissions and, more broadly, to the negative impact of human activities on the environment,” Boyer says. “It also hasn’t been as disrupted by software, cloud computing, AI, and robotics as other industries. That combination really excites us.”

    Through their conversations, the founders learned herbicides are becoming less effective as weeds develop genetic resistance. The only alternative is to hire more workers, which itself was becoming more difficult for farmers.

    “Labor is extremely tight,” says Boyer, adding that bending over and weeding for 10 hours a day is one of the hardest jobs out there. “The labor supply is shrinking if not collapsing in the U.S., and it’s a worldwide trend. That has real environmental implications because of the tradeoff [between labor and herbicides].”

    The problem is especially acute for farmers of specialty crops, including many fruits, vegetables, and nuts, which grow on smaller farms than corn and soybean and each require slightly different growing practices, limiting the effectiveness of many technical and chemical solutions.

    “We don’t harvest corn by hand today, but we still harvest lettuces and nuts and apples by hand,” Boyer says.

    The Titan was built to complement field workers’ efforts to grow and maintain crops. An operator directs it using an iPad, walking alongside the machine and inspecting progress. Both the Titan and Vulcan are powered by an AI that directs hundreds of tiny blades to snip out weeds around each crop. The Vulcan is controlled directly from the tractor cab, where the operator has a touchscreen interface Boyer compares to those found in a Tesla.

    With more than 15,000 commercial hours under its belt, FarmWise hopes the data it collects can be used for more than just weeding in the near future.

    “It’s all about precision,” Boyer says. “We’re going to better understand what the plant needs and make smarter decisions for each one. That will bring us to a point where we can use the same amount of land, much less water, almost no chemicals, much less fertilizer, and still produce more food than we’re producing today. That’s the mission. That’s what excites me.”

    Weeding out farming challenges

    A customer recently told Boyer that without the Titan, he would have to switch all of his organic crops back to conventional because he couldn’t find enough workers.

    “That’s happening with a lot of customers,” Boyer says. “They have no choice but to rely on herbicides. Acres are staying organic because of our product, and conventional farms are reducing their use of herbicides.”

    Now FarmWise is expanding its database to support weeding for six to 12 new crops each year, and Boyer says adding new crops is getting easier and easier for its system.

    As early partners have sought to expand their deployments, Boyer says the only thing limiting the company’s growth is how fast it can build new robots. FarmWise’s new machines will begin being deployed later this year.

    Although the hulking Titan robots are the face of the company today, the founders hope to leverage the data they’ve collected to further improve farming operations.

    “The mission of the company is to turn AI into a tool that is as reliable and dependable as GPS is now in the farming industry,” Boyer says. “Twenty-five years ago, GPS was a very complicated technology. You had to connect to satellites and do some crazy computation to define your position. But a few companies brought GPS to a new level of reliability and simplicity. Today, every farmer in the world uses GPS. We think AI can have an even deeper impact than GPS has had on the farming industry, and we want to be the company that makes it available and easy to use for every farmer in the world.” More

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    Manufacturing a cleaner future

    Manufacturing had a big summer. The CHIPS and Science Act, signed into law in August, represents a massive investment in U.S. domestic manufacturing. The act aims to drastically expand the U.S. semiconductor industry, strengthen supply chains, and invest in R&D for new technological breakthroughs. According to John Hart, professor of mechanical engineering and director of the Laboratory for Manufacturing and Productivity at MIT, the CHIPS Act is just the latest example of significantly increased interest in manufacturing in recent years.

    “You have multiple forces working together: reflections from the pandemic’s impact on supply chains, the geopolitical situation around the world, and the urgency and importance of sustainability,” says Hart. “This has now aligned incentives among government, industry, and the investment community to accelerate innovation in manufacturing and industrial technology.”

    Hand-in-hand with this increased focus on manufacturing is a need to prioritize sustainability.

    Roughly one-quarter of greenhouse gas emissions came from industry and manufacturing in 2020. Factories and plants can also deplete local water reserves and generate vast amounts of waste, some of which can be toxic.

    To address these issues and drive the transition to a low-carbon economy, new products and industrial processes must be developed alongside sustainable manufacturing technologies. Hart sees mechanical engineers as playing a crucial role in this transition.

    “Mechanical engineers can uniquely solve critical problems that require next-generation hardware technologies, and know how to bring their solutions to scale,” says Hart.

    Several fast-growing companies founded by faculty and alumni from MIT’s Department of Mechanical Engineering offer solutions for manufacturing’s environmental problem, paving the path for a more sustainable future.

    Gradiant: Cleantech water solutions

    Manufacturing requires water, and lots of it. A medium-sized semiconductor fabrication plant uses upward of 10 million gallons of water a day. In a world increasingly plagued by droughts, this dependence on water poses a major challenge.

    Gradiant offers a solution to this water problem. Co-founded by Anurag Bajpayee SM ’08, PhD ’12 and Prakash Govindan PhD ’12, the company is a pioneer in sustainable — or “cleantech” — water projects.

    As doctoral students in the Rohsenow Kendall Heat Transfer Laboratory, Bajpayee and Govindan shared a pragmatism and penchant for action. They both worked on desalination research — Bajpayee with Professor Gang Chen and Govindan with Professor John Lienhard.

    Inspired by a childhood spent during a severe drought in Chennai, India, Govindan developed for his PhD a humidification-dehumidification technology that mimicked natural rainfall cycles. It was with this piece of technology, which they named Carrier Gas Extraction (CGE), that the duo founded Gradiant in 2013.

    The key to CGE lies in a proprietary algorithm that accounts for variability in the quality and quantity in wastewater feed. At the heart of the algorithm is a nondimensional number, which Govindan proposes one day be called the “Lienhard Number,” after his doctoral advisor.

    “When the water quality varies in the system, our technology automatically sends a signal to motors within the plant to adjust the flow rates to bring back the nondimensional number to a value of one. Once it’s brought back to a value of one, you’re running in optimal condition,” explains Govindan, who serves as chief operating officer of Gradiant.

    This system can treat and clean the wastewater produced by a manufacturing plant for reuse, ultimately conserving millions of gallons of water each year.

    As the company has grown, the Gradiant team has added new technologies to their arsenal, including Selective Contaminant Extraction, a cost-efficient method that removes only specific contaminants, and a brine-concentration method called Counter-Flow Reverse Osmosis. They now offer a full technology stack of water and wastewater treatment solutions to clients in industries including pharmaceuticals, energy, mining, food and beverage, and the ever-growing semiconductor industry.

    “We are an end-to-end water solutions provider. We have a portfolio of proprietary technologies and will pick and choose from our ‘quiver’ depending on a customer’s needs,” says Bajpayee, who serves as CEO of Gradiant. “Customers look at us as their water partner. We can take care of their water problem end-to-end so they can focus on their core business.”

    Gradiant has seen explosive growth over the past decade. With 450 water and wastewater treatment plants built to date, they treat the equivalent of 5 million households’ worth of water each day. Recent acquisitions saw their total employees rise to above 500.

    The diversity of Gradiant’s solutions is reflected in their clients, who include Pfizer, AB InBev, and Coca-Cola. They also count semiconductor giants like Micron Technology, GlobalFoundries, Intel, and TSMC among their customers.

    “Over the last few years, we have really developed our capabilities and reputation serving semiconductor wastewater and semiconductor ultrapure water,” says Bajpayee.

    Semiconductor manufacturers require ultrapure water for fabrication. Unlike drinking water, which has a total dissolved solids range in the parts per million, water used to manufacture microchips has a range in the parts per billion or quadrillion.

    Currently, the average recycling rate at semiconductor fabrication plants — or fabs — in Singapore is only 43 percent. Using Gradiant’s technologies, these fabs can recycle 98-99 percent of the 10 million gallons of water they require daily. This reused water is pure enough to be put back into the manufacturing process.

    “What we’ve done is eliminated the discharge of this contaminated water and nearly eliminated the dependence of the semiconductor fab on the public water supply,” adds Bajpayee.

    With new regulations being introduced, pressure is increasing for fabs to improve their water use, making sustainability even more important to brand owners and their stakeholders.

    As the domestic semiconductor industry expands in light of the CHIPS and Science Act, Gradiant sees an opportunity to bring their semiconductor water treatment technologies to more factories in the United States.

    Via Separations: Efficient chemical filtration

    Like Bajpayee and Govindan, Shreya Dave ’09, SM ’12, PhD ’16 focused on desalination for her doctoral thesis. Under the guidance of her advisor Jeffrey Grossman, professor of materials science and engineering, Dave built a membrane that could enable more efficient and cheaper desalination.

    A thorough cost and market analysis brought Dave to the conclusion that the desalination membrane she developed would not make it to commercialization.

    “The current technologies are just really good at what they do. They’re low-cost, mass produced, and they worked. There was no room in the market for our technology,” says Dave.

    Shortly after defending her thesis, she read a commentary article in the journal Nature that changed everything. The article outlined a problem. Chemical separations that are central to many manufacturing processes require a huge amount of energy. Industry needed more efficient and cheaper membranes. Dave thought she might have a solution.

    After determining there was an economic opportunity, Dave, Grossman, and Brent Keller PhD ’16 founded Via Separations in 2017. Shortly thereafter, they were chosen as one of the first companies to receive funding from MIT’s venture firm, The Engine.

    Currently, industrial filtration is done by heating chemicals at very high temperatures to separate compounds. Dave likens it to making pasta by boiling all of the water off until it evaporates and all you are left with is the pasta noodles. In manufacturing, this method of chemical separation is extremely energy-intensive and inefficient.

    Via Separations has created the chemical equivalent of a “pasta strainer.” Rather than using heat to separate, their membranes “strain” chemical compounds. This method of chemical filtration uses 90 percent less energy than standard methods.

    While most membranes are made of polymers, Via Separations’ membranes are made with graphene oxide, which can withstand high temperatures and harsh conditions. The membrane is calibrated to the customer’s needs by altering the pore size and tuning the surface chemistry.

    Currently, Dave and her team are focusing on the pulp and paper industry as their beachhead market. They have developed a system that makes the recovery of a substance known as “black liquor” more energy efficient.

    “When tree becomes paper, only one-third of the biomass is used for the paper. Currently the most valuable use for the remaining two-thirds not needed for paper is to take it from a pretty dilute stream to a pretty concentrated stream using evaporators by boiling off the water,” says Dave.

    This black liquor is then burned. Most of the resulting energy is used to power the filtration process.

    “This closed-loop system accounts for an enormous amount of energy consumption in the U.S. We can make that process 84 percent more efficient by putting the ‘pasta strainer’ in front of the boiler,” adds Dave.

    VulcanForms: Additive manufacturing at industrial scale

    The first semester John Hart taught at MIT was a fruitful one. He taught a course on 3D printing, broadly known as additive manufacturing (AM). While it wasn’t his main research focus at the time, he found the topic fascinating. So did many of the students in the class, including Martin Feldmann MEng ’14.

    After graduating with his MEng in advanced manufacturing, Feldmann joined Hart’s research group full time. There, they bonded over their shared interest in AM. They saw an opportunity to innovate with an established metal AM technology, known as laser powder bed fusion, and came up with a concept to realize metal AM at an industrial scale.

    The pair co-founded VulcanForms in 2015.

    “We have developed a machine architecture for metal AM that can build parts with exceptional quality and productivity,” says Hart. “And, we have integrated our machines in a fully digital production system, combining AM, postprocessing, and precision machining.”

    Unlike other companies that sell 3D printers for others to produce parts, VulcanForms makes and sells parts for their customers using their fleet of industrial machines. VulcanForms has grown to nearly 400 employees. Last year, the team opened their first production factory, known as “VulcanOne,” in Devens, Massachusetts.

    The quality and precision with which VulcanForms produces parts is critical for products like medical implants, heat exchangers, and aircraft engines. Their machines can print layers of metal thinner than a human hair.

    “We’re producing components that are difficult, or in some cases impossible to manufacture otherwise,” adds Hart, who sits on the company’s board of directors.

    The technologies developed at VulcanForms may help lead to a more sustainable way to manufacture parts and products, both directly through the additive process and indirectly through more efficient, agile supply chains.

    One way that VulcanForms, and AM in general, promotes sustainability is through material savings.

    Many of the materials VulcanForms uses, such as titanium alloys, require a great deal of energy to produce. When titanium parts are 3D-printed, substantially less of the material is used than in a traditional machining process. This material efficiency is where Hart sees AM making a large impact in terms of energy savings.

    Hart also points out that AM can accelerate innovation in clean energy technologies, ranging from more efficient jet engines to future fusion reactors.

    “Companies seeking to de-risk and scale clean energy technologies require know-how and access to advanced manufacturing capability, and industrial additive manufacturing is transformative in this regard,” Hart adds.

    LiquiGlide: Reducing waste by removing friction

    There is an unlikely culprit when it comes to waste in manufacturing and consumer products: friction. Kripa Varanasi, professor of mechanical engineering, and the team at LiquiGlide are on a mission to create a frictionless future, and substantially reduce waste in the process.

    Founded in 2012 by Varanasi and alum David Smith SM ’11, LiquiGlide designs custom coatings that enable liquids to “glide” on surfaces. Every last drop of a product can be used, whether it’s being squeezed out of a tube of toothpaste or drained from a 500-liter tank at a manufacturing plant. Making containers frictionless substantially minimizes wasted product, and eliminates the need to clean a container before recycling or reusing.

    Since launching, the company has found great success in consumer products. Customer Colgate utilized LiquiGlide’s technologies in the design of the Colgate Elixir toothpaste bottle, which has been honored with several industry awards for design. In a collaboration with world- renowned designer Yves Béhar, LiquiGlide is applying their technology to beauty and personal care product packaging. Meanwhile, the U.S. Food and Drug Administration has granted them a Device Master Filing, opening up opportunities for the technology to be used in medical devices, drug delivery, and biopharmaceuticals.

    In 2016, the company developed a system to make manufacturing containers frictionless. Called CleanTanX, the technology is used to treat the surfaces of tanks, funnels, and hoppers, preventing materials from sticking to the side. The system can reduce material waste by up to 99 percent.

    “This could really change the game. It saves wasted product, reduces wastewater generated from cleaning tanks, and can help make the manufacturing process zero-waste,” says Varanasi, who serves as chair at LiquiGlide.

    LiquiGlide works by creating a coating made of a textured solid and liquid lubricant on the container surface. When applied to a container, the lubricant remains infused within the texture. Capillary forces stabilize and allow the liquid to spread on the surface, creating a continuously lubricated surface that any viscous material can slide right down. The company uses a thermodynamic algorithm to determine the combinations of safe solids and liquids depending on the product, whether it’s toothpaste or paint.

    The company has built a robotic spraying system that can treat large vats and tanks at manufacturing plants on site. In addition to saving companies millions of dollars in wasted product, LiquiGlide drastically reduces the amount of water needed to regularly clean these containers, which normally have product stuck to the sides.

    “Normally when you empty everything out of a tank, you still have residue that needs to be cleaned with a tremendous amount of water. In agrochemicals, for example, there are strict regulations about how to deal with the resulting wastewater, which is toxic. All of that can be eliminated with LiquiGlide,” says Varanasi.

    While the closure of many manufacturing facilities early in the pandemic slowed down the rollout of CleanTanX pilots at plants, things have picked up in recent months. As manufacturing ramps up both globally and domestically, Varanasi sees a growing need for LiquiGlide’s technologies, especially for liquids like semiconductor slurry.

    Companies like Gradiant, Via Separations, VulcanForms, and LiquiGlide demonstrate that an expansion in manufacturing industries does not need to come at a steep environmental cost. It is possible for manufacturing to be scaled up in a sustainable way.

    “Manufacturing has always been the backbone of what we do as mechanical engineers. At MIT in particular, there is always a drive to make manufacturing sustainable,” says Evelyn Wang, Ford Professor of Engineering and former head of the Department of Mechanical Engineering. “It’s amazing to see how startups that have an origin in our department are looking at every aspect of the manufacturing process and figuring out how to improve it for the health of our planet.”

    As legislation like the CHIPS and Science Act fuels growth in manufacturing, there will be an increased need for startups and companies that develop solutions to mitigate the environmental impact, bringing us closer to a more sustainable future. More

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    MIT scientists contribute to National Ignition Facility fusion milestone

    On Monday, Dec. 5, at around 1 a.m., a tiny sphere of deuterium-tritium fuel surrounded by a cylindrical can of gold called a hohlraum was targeted by 192 lasers at the National Ignition Facility (NIF) at Lawrence Livermore National Laboratory (LLNL) in California. Over the course of billionths of a second, the lasers fired, generating X-rays inside the gold can, and imploding the sphere of fuel.

    On that morning, for the first time ever, the lasers delivered 2.1 megajoules of energy and yielded 3.15 megajoules in return, achieving a historic fusion energy gain well above 1 — a result verified by diagnostic tools developed by the MIT Plasma Science and Fusion Center (PSFC). The use of these tools and their importance was referenced by Arthur Pak, a LLNL staff scientist who spoke at a U.S. Department of Energy press event on Dec. 13 announcing the NIF’s success.

    Johan Frenje, head of the PSFC High-Energy-Density Physics division, notes that this milestone “will have profound implications for laboratory fusion research in general.”

    Since the late 1950s, researchers worldwide have pursued fusion ignition and energy gain in a laboratory, considering it one of the grand challenges of the 21st century. Ignition can only be reached when the internal fusion heating power is high enough to overcome the physical processes that cool the fusion plasma, creating a positive thermodynamic feedback loop that very rapidly increases the plasma temperature. In the case of inertial confinement fusion, the method used at the NIF, ignition can initiate a “fuel burn propagation” into the surrounding dense and cold fuel, and when done correctly, enable fusion-energy gain.

    Frenje and his PSFC division initially designed dozens of diagnostic systems that were implemented at the NIF, including the vitally important magnetic recoil neutron spectrometer (MRS), which measures the neutron energy spectrum, the data from which fusion yield, plasma ion temperature, and spherical fuel pellet compression (“fuel areal density”) can be determined. Overseen by PSFC Research Scientist Maria Gatu Johnson since 2013, the MRS is one of two systems at the NIF relied upon to measure the absolute neutron yield from the Dec. 5 experiment because of its unique ability to accurately interpret an implosion’s neutron signals.

    “Before the announcement of this historic achievement could be made, the LLNL team wanted to wait until Maria had analyzed the MRS data to an adequate level for a fusion yield to be determined,” says Frenje.

    Response around MIT to NIF’s announcement has been enthusiastic and hopeful. “This is the kind of breakthrough that ignites the imagination,” says Vice President for Research Maria Zuber, “reminding us of the wonder of discovery and the possibilities of human ingenuity. Although we have a long, hard path ahead of us before fusion can deliver clean energy to the electrical grid, we should find much reason for optimism in today’s announcement. Innovation in science and technology holds great power and promise to address some of the world’s biggest challenges, including climate change.”

    Frenje also credits the rest of the team at the PSFC’s High-Energy-Density Physics division, the Laboratory for Laser Energetics at the University of Rochester, LLNL, and other collaborators for their support and involvement in this research, as well as the National Nuclear Security Administration of the Department of Energy, which has funded much of their work since the early 1990s. He is also proud of the number of MIT PhDs that have been generated by the High-Energy-Density Physics Division and subsequently hired by LLNL, including the experimental lead for this experiment, Alex Zylstra PhD ’15.

    “This is really a team effort,” says Frenje. “Without the scientific dialogue and the extensive know-how at the HEDP Division, the critical contributions made by the MRS system would not have happened.” More

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    Using game engines and “twins” to co-create stories of climate futures

    Imagine entering a 3D virtual story world that’s a digital twin of an existing physical space but also doubles as a vessel to dream up speculative climate stories and collective designs. Then, those imagined worlds are translated back into concrete plans for our physical spaces.

    Five multidisciplinary teams recently convened at MIT — virtually — for the inaugural WORLDING workshop. In a weeklong series of research and development gatherings, the teams met with MIT scientists, staff, fellows, students and graduates as well as other leading figures in the field. The theme of the gathering was “story, space, climate, and game engines.”

    “WORLDING illustrates the emergence of an entirely new field that fuses urban planning, climate science, real-time 3D engines, nonfiction storytelling, and speculative fiction,” says Katerina Cizek, lead designer of the workshop at Co-Creation Studio, MIT Open Documentary Lab. “And co-creation is at the core of this field that allows for collective, democratic, scientific and artistic processes.” The research workshop was organized by the studio in partnership with Unity Software.

    The WORLDING teams met with MIT scholars to discuss diverse domains, from the decolonization of board games, to urban planning as acts of democracy, to behind the scenes of a flagship MIT Climate Challenge project.

    “Climate is really a whole-world initiative,” said Noelle Selin, an MIT atmospheric chemistry professor, in a talk at WORLDING. Selin co-leads an MIT initiative that is digitally twinning the Earth to harness enormous volumes of data for improved climate projections and put these models into the hands of diverse communities and stakeholders.

    “Digital twinning” is a growth market for the game engine industry, in verticals such as manufacturing, architecture, finance, and medicine. “Digital twinning gives teams the power to ideate,” said Elizabeth Baron, a senior manager of enterprise solutions at Unity in her talk at WORLDING. “You can look at many things that maybe aren’t even possible to produce. But you’re the resource. Impact is very low, but the creativity aspect is very high.”

    That’s where the story and media experts come in. “Now, more than ever, we need to forge shared narratives about the world that we live in today and the world that we want to build for the future. Technology can help us visualize and communicate those worlds,” says Marina Psaros MCP ’06, head of sustainability at Unity, lead on WORLDING at Unity, and a graduate of the MIT Department of Urban Studies and Planning.

    In his talk on the short history of WORLDING, media scholar William Uricchio, MIT professor of comparative media studies and founder of the Open Documentary Lab, suggested that story and space come together in these projects that create new ways of knowing. “Story is always a representation,” he says. “It’s got a fixity and coherence to it, and play is — and, I would argue, worlds are —  all about simulation. Simulation in the case of digital twinning is capable of generating countless stories. It’s play as a story-generator, but in the service of envisioning a pluralistic and malleable future.”

    Fixed dominant narratives and game mechanics that underpin board games have been historically violent and unjust, says MIT Game Lab scholar Mikael Jakkobson, who shared findings for his upcoming book on the subject with the cohort. He argues that board games are built on underlying ideas of  “exploration, expansion, exploitation, and extermination. And, as it happens, those are also good ways of thinking about the mechanics of Western colonialism.”

    To counter these hegemonic mechanics and come up with new systems, community is vital, and urban planning is a discipline that plays a huge role in the translation of space, story, and democracy. Ceasar MacDowell, an MIT professor of the practice of civic design, told the WORLDING cohort that urban planning needs to expand its notion of authorship. He is working on systems (from his current position at the Media Lab) that not only engage the community in conversations but also prompt “the people who have been in conversations to actually make sense of them, do the meaning-making themselves, not to have external people interpret them.” These become dynamic layers of both representation and simulation that are not, as Uricchio suggests, fixed. 

    USAID Chief Climate Officer Gillian Calwell visited the group with both sharp warnings and warm enthusiasm: “When it comes to climate, this world isn’t working so well for us; we better start envisioning the new ones, and fast … We don’t have time to convince people that this is happening anymore. Nor do we need to. I think most of the world is having the hands-on, up-close-and-personal experience with the fact that these impacts are coming faster and more furiously than even the scientists had predicted. But one thing we do need help with on a more hopeful note is visualizing how the world could be different.”

    The WORLDING workshop is designed and inspired by the ideas and practices charted in the Co-Creation Studio’s new MIT Press book, “Collective Wisdom: Co-Creation Media for Equity and Justice,” which insists that “No one person, organization, or discipline can determine all the answers alone.”

    The five multidisciplinary teams in this first WORLDING cohort were diverse in approach, technology, and geography. For example, one is an Indigenous-led, land-based, site-specific digital installation that seeks to envision a future in which, once again, the great herds of buffalo walk freely. Another team is creating 3D-modeled biome kits of the water systems in the drought-stricken American West, animated by interviews and data from the communities living there. Yet another team is digitally twinning and then re-imagining a sustainable future in the year 2180 for a multi-player virtual reality game in a Yawanawà Shukuvena Village in the rainforests of Brazil.

    “While our workshop design was focused on developing and researching these incredible, interdisciplinary projects, we also hope that WORLDING can set an example for similar initiatives across global sectors where distances and varied expertise are not limitations but opportunities to learn from one another,” says Srushti Kamat, WORLDING producer and MIT creative media studies/writing grad.

    Most of the talks and presentations from the WORLDING workshop are available as archived videos at cocreationstudio.mit.edu/worlding-videos. More

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    Pesticide innovation takes top prize at Collegiate Inventors Competition

    On Oct. 12, MIT mechanical engineering alumnus Vishnu Jayaprakash SM ’19, PhD ’22 was named the first-place winner in the graduate category of the Collegiate Inventors Competition. The annual competition, which is organized by the National Inventors Hall of Fame, celebrates college and university student inventors. Jayaprakash won for his pesticide innovation AgZen-Cloak, which he developed while he was a student in the lab of Kripa Varanasi, a professor of mechanical engineering.

    Currently, only 2 percent of pesticide spray is retained by crops. Many crops are naturally water-repellent, causing pesticide-laden water to bounce off of them. Farmers are forced to over-spray significantly to ensure proper spray coverage on their crops. Not only does this waste expensive pesticides, but it also comes at an environmental cost.

    Runoff from pesticide treatment pollutes soil and nearby streams. Droplets can travel in the air, leading to illness and death in nearby populations. It is estimated that each year, pesticide pollution causes between 20,000 and 200,000 deaths, and up to 385 million acute illnesses like cancer, birth defects, and neurological conditions.   

    With his invention AgZen-Cloak, Jayaprakash has found a way to keep droplets of water containing pesticide from bouncing off crops by “cloaking” the droplets in a small amount of plant-derived oil. As a result, farmers could use just one-fifth the amount of spray, minimizing water waste and cost for farmers and eliminating airborne pollution and toxic runoff. It also improves pesticide retention, which can lead to higher crop yield.

    “By cloaking each droplet with a minute quantity of a plant-based oil, we promote water retention on even the most water-repellent plant surfaces,” says Jayaprakash. “AgZen-Cloak presents a universal, inexpensive, and environmentally sustainable way to prevent pesticide overuse and waste.”

    Farming is in Jayaprakash’s DNA. His family operates a 10-acre farm near Chennai, India, where they grow rice and mangoes. Upon joining the Varanasi Research Group as a graduate student, Jayaprakash was instantly drawn to Varanasi’s work on pesticides in agriculture.

    “Growing up, I would spray crops on my family farm wearing a backpack sprayer. So, I’ve always wanted to work on research that made farmer’s lives easier,” says Jayaprakash, who serves as CEO of the startup AgZen.

    Play video

    2022 World Food Day First Prize Winner – AgZen Cloak: Reducing Pesticide Pollution and Waste

    Helping droplets stick

    Varanasi and his lab at MIT work on what is known as interfacial phenomena — or the study of what happens when different phases come into contact and interact with one another. Understanding how a liquid interacts with a solid or how a liquid reacts to a certain gas has endless applications, which explains the diversity of the research Varanasi has conducted over the years. He and his team have developed solutions for everything from consumer product packaging to power plant emissions.

    In 2009, Varanasi gave a talk at the U.S. Department of Agriculture (USDA). There, he learned from the USDA just how big of a problem runoff from pesticide spray was for farmers around the world.
    A green cabbage leaf is treated with pesticide-laden water using conventional spraying. Image courtesy of AgZen.A green cabbage leaf is treated with pesticide-laden water using AgZen’s technology. By cloaking droplets in a tiny amount of plant-derived oil, the droplets stick to the leaf, minimizing over-spraying, waste, and pollution. Image courtesy of AgZen.He enlisted the help of then-graduate student Maher Damak SM ’15, PhD ’18 to apply their work in interfacial phenomena to pesticide sprays. Over the next several years, the Varanasi Research Group developed a technology that utilized electrically charged polymers to keep droplets from bouncing off hydrophobic surfaces. When droplets containing positively and negatively charged additives meet, their surface chemistry allows them to stick to a plant’s surface.

    Using polyelectrolytes, the researchers could reduce the amount of spray needed to cover a crop by tenfold in the lab. This motivated the Varanasi Research Group to pursue three years of field trials with various commercial growers around the world, where they were able to demonstrate significant savings for farmers.

    “We got fantastic feedback on our technology from farmers. We are really excited to change the paradigm for agriculture. Not only is it good for the environment, but we’ve heard from farmers that they love it. If we can put money back into farms, it helps society as a whole,” adds Varanasi.

    In response to the positive feedback, Varanasi and Jayaprakash co-founded startup AgZen in 2020. 

    When field testing their polyelectrolyte technology, Varanasi and Jayaprakash came up with the idea to explore the use of a fully plant-based material to help farmers achieve the same savings. 

    Cloaking droplets and engineering nozzles

    Jayaprakash found that by cloaking a small amount of plant-derived oil around a water droplet, droplets stick to plant surfaces that would typically repel water. After conducting many studies in the lab, he found that the oil only needs to make up 0.1 percent of a droplet’s total volume to stick to crops and provide total, uniform coverage.

    While his cloaking solution worked in the lab, Jayaprakash knew that to have a tangible impact in the real world he needed to find an easy, low-cost way for farmers to coat pesticide spray droplets in oil.

    Jayaprakash focused on spray nozzles. He developed a proprietary nozzle that coats each droplet with a small amount of oil as they are being formed. The nozzles can easily be added to any hose or farming equipment.

    “What we’ve done is figured out a smart way to cloak these droplets by using a very small quantity of oil on the outside of each drop. Because of that, we get this drastic improvement in performance that can really be a game-changer for farmers,” says Jayaprakash.

    In addition to improving pesticide retention in crops, the AgZen-Cloak solves a second problem. Since large droplets are prone to break apart and bounce off crops, historically, farmers have sprayed pesticide in tiny, mist-like droplets. These fine droplets are often carried by the wind, increasing pesticide pollution in nearby areas. 

    When AgZen-Cloak is used, the pesticide-laden droplets can be larger and still stick to crops. These larger droplets aren’t carried by the wind, decreasing the risk of pollution and minimizing the health impacts on local populations.  

    “We’re actually solving two problems with one solution. With the cloaking technology, we can spray much larger droplets that aren’t prone to wind drift and they can stick to the plant,” Jayaprakash adds.

    Bringing AgZen-Cloaks to farmers around the world

    This spring, Varanasi encouraged Jayaprakash to submit AgZen-Cloak to the Collegiate Inventors Competition. Out of hundreds of applications, Jayaprakash was one of 25 student inventors to be chosen as a finalist.

    On Oct. 12, Jayaprakash presented his technology to a panel of judges composed of National Inventors Hall of Fame inductees and U.S. Patent and Trademark Office officials. Meeting with such an illustrious group of inventors and officials left an impression on Jayaprakash.

    “These are people who have invented things that have changed the world. So, to get their feedback on what we’re doing was incredibly valuable,” he says. Jayaprakash received a $10,000 prize for being named the first-place graduate winner.

    As full-time CEO of AgZen, Jayaprakash is shifting focus to field testing and commercialization. He and the AgZen team have already conducted field testing across the world at locations including a Prosecco vineyard outside of Venice, a ranch in California, and Ward’s Berry Farm in Sharon, Massachusetts. The University of Massachusetts at Amherst’s vegetable extension program, led by their program director Susan Scheufele, recently concluded a field test that validated AgZen’s on-field performance.

    Two days after his win at the Collegiate Inventors Competition, Jayaprakash was named the first prize winner of the MIT Abdul Latif Jamel Water and Food Systems Lab World Food Day student video competition. Hours later, he flew across the country to attend an agricultural tech conference in California, eager to meet with farmers and discuss plans for rolling out AgZen’s innovations to farms everywhere. More

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    Studying floods to better predict their dangers

    “My job is basically flooding Cambridge,” says Katerina “Katya” Boukin, a graduate student in civil and environmental engineering at MIT and the MIT Concrete Sustainability Hub’s resident expert on flood simulations. 

    You can often find her fine-tuning high-resolution flood risk models for the City of Cambridge, Massachusetts, or talking about hurricanes with fellow researcher Ipek Bensu Manav.

    Flooding represents one of the world’s gravest natural hazards. Extreme climate events inducing flooding, like severe storms, winter storms, and tropical cyclones, caused an estimated $128.1 billion of damages in 2021 alone. 

    Climate simulation models suggest that severe storms will become more frequent in the coming years, necessitating a better understanding of which parts of cities are most vulnerable — an understanding that can be improved through modeling.

    A problem with current flood models is that they struggle to account for an oft-misunderstood type of flooding known as pluvial flooding. 

    “You might think of flooding as the overflowing of a body of water, like a river. This is fluvial flooding. This can be somewhat predictable, as you can think of proximity to water as a risk factor,” Boukin explains.

    However, the “flash flooding” that causes many deaths each year can happen even in places nowhere near a body of water. This is an example of pluvial flooding, which is affected by terrain, urban infrastructure, and the dynamic nature of storm loads.

    “If we don’t know how a flood is propagating, we don’t know the risk it poses to the urban environment. And if we don’t understand the risk, we can’t really discuss mitigation strategies,” says Boukin, “That’s why I pursue improving flood propagation models.”

    Boukin is leading development of a new flood prediction method that seeks to address these shortcomings. By better representing the complex morphology of cities, Boukin’s approach may provide a clearer forecast of future urban flooding.

    Katya Boukin developed this model of the City of Cambridge, Massachusetts. The base model was provided through a collaboration between MIT, the City of Cambridge, and Dewberry Engineering.

    Image: Katya Boukin

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    “In contrast to the more typical traditional catchment model, our method has rainwater spread around the urban environment based on the city’s topography, below-the-surface features like sewer pipes, and the characteristics of local soils,” notes Boukin.

    “We can simulate the flooding of regions with local rain forecasts. Our results can show how flooding propagates by the foot and by the second,” she adds.

    While Boukin’s current focus is flood simulation, her unconventional academic career has taken her research in many directions, like examining structural bottlenecks in dense urban rail systems and forecasting ground displacement due to tunneling. 

    “I’ve always been interested in the messy side of problem-solving. I think that difficult problems present a real chance to gain a deeper understanding,” says Boukin.

    Boukin credits her upbringing for giving her this perspective. A native of Israel, Boukin says that civil engineering is the family business. “My parents are civil engineers, my mom’s parents are, too, her grandfather was a professor in civil engineering, and so on. Civil engineering is my bloodline.”

    However, the decision to follow the family tradition did not come so easily. “After I took the Israeli equivalent of the SAT, I was at a decision point: Should I go to engineering school or medical school?” she recalls.

    “I decided to go on a backpacking trip to help make up my mind. It’s sort of an Israeli rite to explore internationally, so I spent six months in South America. I think backpacking is something everyone should do.”

    After this soul searching, Boukin landed on engineering school, where she fell in love with structural engineering. “It was the option that felt most familiar and interesting. I grew up playing with AutoCAD on the family computer, and now I use AutoCAD professionally!” she notes.

    “For my master’s degree, I was looking to study in a department that would help me integrate knowledge from fields like climatology and civil engineering. I found the MIT Department of Civil and Environmental Engineering to be an excellent fit,” she says.

    “I am lucky that MIT has so many people that work together as well as they do. I ended up at the Concrete Sustainability Hub, where I’m working on projects which are the perfect fit between what I wanted to do and what the department wanted to do.” 

    Boukin’s move to Cambridge has given her a new perspective on her family and childhood. 

    “My parents brought me to Israel when I was just 1 year old. In moving here as a second-time immigrant, I have a new perspective on what my parents went through during the move to Israel. I moved when I was 27 years old, the same age as they were. They didn’t have a support network and worked any job they could find,” she explains.

    “I am incredibly grateful to them for the morals they instilled in my sister, who recently graduated medical school, and I. I know I can call my parents if I ever need something, and they will do whatever they can to help.”

    Boukin hopes to honor her parents’ efforts through her research.

    “Not only do I want to help stakeholders understand flood risks, I want to make awareness of flooding more accessible. Each community needs different things to be resilient, and different cultures have different ways of delivering and receiving information,” she says.

    “Everyone should understand that they, in addition to the buildings and infrastructure around them, are part of a complex ecosystem. Any change to a city can affect the rest of it. If designers and residents are aware of this when considering flood mitigation strategies, we can better design cities and understand the consequences of damage.” More