Daniel P. Henkel

Principal Consultant / Ph.D., P.E. / Denver


Dr. Henkel completed his MS and Ph.D. at Lehigh University, where his research areas were physical metallurgy, forensics and non-destructive evaluation. He is also a graduate of Pennsylvania State University in electrical engineering and is a registered professional engineer.

He was formerly a NASA scientist, materials research director, innovation leader, and corporate executive with over 30 years in advanced manufacturing processes and materials engineering. He has numerous publications, obtained four patents, authored a textbook entitled Structure and Properties of Engineering Materials, taught graduate school in applied science, won the prestigious Engineering Materials Achievement Award, and is an elected Fellow of ASM International.

Dr. Henkel’s materials processing expertise includes additive manufacturing (3D printing), welding, casting, injection molding, forming, sintering, heat treatment and microstructural optimization. He developed commercial products using thin film membranes, catalytic nanoparticles, sol-gel coatings, ductile cast iron, and porous ceramics. His product experience spans diverse industries such as: industrial filtration and separation, chemical processing, high/low voltage electrical switches, high vacuum equipment, fuel cells, medical devices, space flight, petrochemical, industrial piping, microelectronics, bridges and highway structures, municipal water systems and aerospace.

Dr. Henkel’s materials’ expertise includes carbon and stainless steels, aluminum alloys, copper/brass, nickel base superalloys, titanium, intermetallics, carbon-reinforced composites, thermoplastic polymers and engineering ceramics. His corrosion experience includes: microbially-induced corrosion (MIC), sulfidation, selective leaching, cavitation, sensitization, oxidation, carburization, chloride stress corrosion cracking, and crevice corrosion.

Education and Certifications

  • Materials Science and Engineering Ph.D.: Lehigh University
  • Metallurgy and Materials Engineering M.S.: Lehigh University
  • Electrical Engineering B.S.: Pennsylvania State University