Materials Scientist, Semiconductor Strategist, SCUBA Diver
Dave Henshall’s career is a powerful example of what it looks like to bring big ideas to life—especially in one of the most advanced and important industries of our time: semiconductors. As the Chief Operating Officer for SMART USA, the newest Manufacturing USA institute, Dave is setting the stage for the future of digital twin semiconductor manufacturing in the United States. That means he’s doing everything from building operations and managing partnerships to setting up HR, IT, research security, and more—basically creating the foundation for a major national innovation effort.
What makes Dave’s career path especially exciting is the way he blends technical expertise with big-picture thinking. With both a B.S. and M.S. in Ceramic Engineering and Materials Science, he started in industry, leading teams and building technologies that made LED lighting more common and efficient. Then, he brought that same drive to the federal government, working at the Defense Advanced Research Projects Agency (DARPA) and the Advanced Research Projects Agency–Energy (ARPA-E) to turn new technologies into real products through manufacturing.
Now, at SMART USA, Dave is using all that experience to connect government, education, and industry, so that new ideas in semiconductor tech can turn into careers, companies, and products that power our lives. He’s not only helping shape the next wave of innovation, he’s helping build the workforce that will drive it.
Dave’s journey shows how a strong technical foundation, curiosity, and a willingness to lead can open doors to shaping the future. David Henshall is a Modern Maker.
Q&A with David
What is the most challenging part of your job?
There are countless interesting topics to explore, but I need to stay disciplined and focus on just a few to ensure I do them well. My former boss once told me, "If you try to do everything, you won't do anything," and that wisdom holds true for SMART USA. While I’d love to tackle everything, I know that spreading myself too thin will only prevent me from making meaningful progress.
What is the best part of your job?
Can I pick two? First and foremost, I’m inspired by the incredible people I work with every day—truly the best in the world at what they do. Their expertise and dedication motivate me and challenge me to do my best. Second, the significance of our mission drives me. Expanding domestic semiconductor manufacturing is vital to our nation’s economy and national security. Semiconductors are the backbone of modern society and essential to national defense. Getting this right is critical, and I’m excited to be contributing to such an important effort for our country and society.
What would people be surprised to learn about manufacturing or your role in manufacturing?
Most people don't realize how important semiconductors are to the way we live our lives, we're literally dependent on them for food, health, transportation, communication, and entertainment.
What advice do you have for someone new to the industry or considering manufacturing as a career?
Find a way to get involved, manufacturing is a great way to build a career and have an impact on people's lives.
What makes you excited to go to work on Mondays?
Similar to before, the people I work with and the objectives we're working to accomplish. My colleagues at SMART USA, our federal partners, and the partners that are trying to help us build this make for something to look forward to on Monday mornings.
What are the three most important skills for your job?
- Clear Communication: Effectively convey complex and abstract ideas in a simplified way so that newcomers can quickly understand. This means helping others grasp in minutes what took us months or years to learn and refine.
- Staying Organized: With multiple people, organizations, and activities evolving rapidly, keeping track of everything is essential. Maintaining organization ensures informed and accurate decision-making in a fast-changing environment.
- Understanding Motivations: Recognizing what drives individuals and organizations allows for the design of concepts and solutions that provide meaningful value to all stakeholders.
If you didn’t have to work, how would you spend your day?
Hopefully talking with the same people I talk to now, and figuring out how to develop digital twins for semiconductor manufacturing. It's an inspiring topic!
What activity gives you the most energy?
Pushing myself outside of my comfort zone, doing activities that I'm uncomfortable with.
What hobbies make you better at your career?
Overall I like to explore and try new things. I recently became certified on SCUBA diving and really enjoy exploring areas where most people can't readily see. I also like the thrill of the risk associated with it.
How does the work you do impact the world?
As mentioned earlier, semiconductors are the foundation of modern society. Helping to make the cost lower, the performance better, and the reliability higher helps people live longer, healthier, safer, and more enriched lives.
