If You Can Think It, You Can Make It

3D Design and Fabrication course is part of a growing STEM program

Jon Marlow has a message for students intimidated by the prospect of designing and creating objects using Computer-aided Design, CNC milling, lasering and 3-D printing: don’t be. “You don’t need to be a scientist or engineer to take this class,” said the Science Department Chair, who has taught 3-D Design and Fabrication, a Summer Phase course the past four years. “If you have a creative mind and can think of an idea, then you can make it.”

“I always wanted to take the class,” said Mekhai Hilaire ’25, who was happy to land a spot in the five-week 2024 course. He liked the idea of, “putting pieces together,” to create something tangible. One of Mr. Marlow’s goals for the class is for Gray Bees to gain exposure to the art and science of the manufacturing process, and to actively test and apply their knowledge, from concept and design to finished product.

 Vertical Learning Curve

The first project is a straightforward one according to Mr. Marlow. “Something simple that kids can print within 20 to 30 minutes on the 3-D printer that gives them some immediate feedback. They can see if the thing they envisioned turned out right,” he explained. Even simple designs can have a vertical learning curve, something Mekhai, Anthony Isin ’25 and Sebastian Andreason ’26 encountered early on. “You have to be really precise with the measurements and the scale,” recalled Anthony, whose first project was a simple, three- dimensional figurine. “In the software [on screen] the object you’re designing may look big. In reality, when I printed my first figurine it turned out really small.”

Students work up to projects involving laser engraving and Computer Numerical Control milling, a tool that designers and programmers use to create precise parts from a block of material, using computer-generated instructions. “You definitely have to pay attention to detail when it comes to setting up the machine,” said Mekhai. “Otherwise, you have to start all over again.” 

“It’s a really good class and a fun change of pace,” said Sebastian, who worked his way from a simple box with his initials to a multi-faceted dinosaur. Rendering parts for more advanced projects is also time consuming, which is why Mr. Marlow plans to turn 3-D Design and Fabrication into a Spring Phase project in 2026. “There’s never enough time,” he said. “During Spring Phase, we have the students for five hours so we can stretch the class out and get a lot done.”

Sebastian agreed. “It would be very cool to have more time to make stuff more complicated and interesting.” As a Spring Phase project, students would also have direct oversight in the 3-D manufacturing process, bolstering critical thinking and problem-solving skill sets.

A Resourceful Start

STEM opportunities are growing at The Hive, in large part because of the resourcefulness of faculty. Mr. Marlow for instance, started 3-D Design and Fabrication by digging out a single 3-D printer he’d heard was stored somewhere on the Property.  As is so often the case at Benedict’s, word spread throughout the community, along with offers of help and support.

Math teacher Craig White ’04 connected Mr. Marlow to Thomas J. Wallin, Ph.D., a college friend and materials engineer who worked on artificial touch sensations at Oculus, a division of Meta. Dr. Wallin, now an assistant professor at MIT, arranged for a generous donation, which was used to upgrade the STEM class. This included the purchase of a 3-in-1 3-D printer and hardware that made CNC milling and laser engraving operational.

Vital investments are also being made in other areas, including the science labs utilized by the Middle, Girls and Boys Prep Divisions. “What do you need to turn your lab space into a more functional area?” Mr. Marlow asked Science Department faculty, who came up with a list of basic improvements to better support a science lab experience that prepares Gray Bees for college.

The Healey Family STEM Fund

In 2017, the Healey STEM Fund was established by Dorothy and John Healey, Ph.D. ’58 to strengthen STEM programs at The Hive. The couple’s son, Sean, also supports the Fund. Dr. Healey, who holds a doctoral degree in structural engineering, has made significant contributions to the profession as an engineering executive, program manager, consulting engineer and researcher. “I can’t think of a better outlet for charitable donations,” he stated. “St. Benedict’s has the right formula for exposing students to STEM opportunities, in order to build a sound foundation for a future career.”  

Dr. Healey, who has made several visits to the Property, said he’s been impressed by Gray Bees’ enthusiasm for STEM and the comprehensive nature of Benedict’s initiatives. In addition to new experiential courses, a growing number of students are earning early college credit in Calculus, engineering, meteorology and other subjects at NJIT, Rutgers-Newark and Project Acceleration with Seton Hall University. Mentoring and internships with industry professionals is also baked into the STEM program through longstanding partnerships with New Jersey’s ACE (Architecture, Construction Engineering) Mentor Program of America and a new student chapter of the National Society of Black Engineers started by math teacher J’Ream Lewis ’10. “It’s a diverse program that’s quite impressive,” said Dr. Healey, which prompted the family to make a supplementary gift to fund the latest facility improvements.

Longer term needs and investments will also be identified to bolster the physical infrastructure for STEM learning. “I’m more than happy to show people around,” said Mr. Marlow. “I think they’ll be surprised by the amount we’re able to get done with the resources we have. It’s a real testament to the creativity of my colleagues in the Science Department. With greater investment in our teachers, our programs and infrastructure, we can build a next level STEM program. For any kid making a decision about high school, or an adult helping them make that decision, our goal is that they look at us and say, “St. Benedict’s has a great Science Department. St. Benedict’s has a great STEM program. I want to go there.”