The manufacturing sector in the United States is at a critical inflection point, requiring brilliant young minds who are ready to tackle modern challenges with innovative, sustainable solutions.
At just 21 years old, Mhakayla Johnson is already working to make the world a better place. Going into her senior year as a mechanical engineering student at Alabama A&M University, she is conducting research on composite materials that are more sustainable and easier to recycle. While interning this summer at the University of Alabama at Birmingham, Johnson was encouraged by her mentor, Dr. Haibin Ning, to attend a METAL bootcamp.
Johnson poses with the skillet she made at the UAB Bootcamp
METAL, led by IACMI – The Composites Institute®, and funded by the Department of War’s Office of Industrial Base Policy, was built to revitalize American manufacturing through hands-on training in casting and forging.
Through K-12 workshops and university bootcamps, METAL introduces students and career seekers to modern metalcasting and forging careers. Participants can complete METAL’s free online training before attending immersive, in-person bootcamps led by professional metallurgists and manufacturing experts across the country.
For five days, UAB bootcamp participants gain hands-on experience in sand casting design and pouring processes. The trainees pound sand into molds, learn CAD software, pour molten metal, and machine-finish parts. Participants leave with their own metal creations, foundational metalcasting and forging skills, and a clearer picture of promising careers in aerospace, automotive and defense manufacturing.
At bootcamp, Johnson gained critical, hands-on experience necessary to transition from classroom theory to real-world application.
“I’m just a hands-on kind of person, you know. I like to work with my hands, I like to build and create stuff and improve things,” she says. Her journey highlights the vital importance of experiential learning in science, technology, engineering, and mathematics (STEM).
Engineering a Sustainable Tomorrow
Johnson’s current research, conducted under the mentorship of Dr. Ning through the REU research program, is deeply focused on manufacturing sustainability. She is actively exploring the creation of composites using cellulose and hemp fibers.
“Dr. Ning told me I should step into the metal bootcamp so I can get my hands dirty and add more knowledge to what I already have,” she said of expanding her materials understanding.
Currently, industries ranging from automotive to aerospace rely heavily on materials like carbon fiber. While highly effective, these materials are notoriously difficult to recycle. By researching viable, sustainable alternatives, Johnson is addressing a critical environmental challenge head-on.
“Recyclability and just making our planet a better place [is important],” Johnson explains. “With carbon fibers… it’s very hard to recycle. And that’s why I’m glad I’m doing the research with Dr. Ning so that we can do research on composites and find different materials, better materials than the ones that are already being used.”
Johnson toured the historic Sloss Furnace site with her UAB Bootcamp classmates.
Nurturing a Lifelong Passion for STEM
Johnson’s journey into science was no accident. Her mother, an Alabama A&M physical science professor, nurtured her passion for building and creating from an early age through robotics and STEM camps. “She didn’t just push me into it; she realized what my interests were as a kid and put me on that path,” Johnson stated.
“I was a really hands-on creative type of kid,” she recalls. “I loved to draw, and I was very artistic… I want to be an engineer, I want to build stuff, I want to make stuff.”
In high school, Johnson began welding and looking into different types of engineering, landing ultimately on mechanical.
Despite identifying as a hands-on creator rather than a natural mathematician, her determination allowed her to excel.
“This might sound crazy,” she said, “but I was never the best at math…I understood it, but it took me more to get there. I had to study a little bit harder and just apply myself a little bit more.”
Her story is a powerful testament to the fact that success in engineering requires immense creativity and perseverance just as much as raw calculation.
Strengthening Foundations
Bootcamp participants take turns processing recently cast pieces.
While Johnson’s research focuses on sustainable composites and natural fibers, a foundational understanding of metallurgy is vital for innovations in material science. By participating in the METAL bootcamp, students like Johnson gain a comprehensive view of how traditional metalcasting interacts with modern materials.
One example of this at UAB involved a project to produce composite screws that could be used on offshore oil rigs while maintaining strength similar to steel. Understanding the science behind both metal and non-metal materials proved vital in this pursuit.
Johnson noted the lab at UAB was a great place to “actually see the real-world applications of what I’m learning.”
METAL Bootcamps also dive into sustainability, teaching students about cleaner melting techniques and demonstrating them, as demonstrated by the use of the induction furnaces at the UAB lab.
Inspiring the Next Generation
As she looks toward her senior year and contemplates furthering her education, Johnson offers advice to aspiring young engineers.
“Keep going and pushing towards your dreams,” she advises. “There’s nothing that you want to do that you can’t do… Take heed to your resources and believe in yourself. Stick to the course, your dreams can come true if you put in the work to achieve them.”