Professor Kalyon'’s research focuses on precision structuring and processing/shaping of complex fluids including polymers and suspensions. This focus, for example, has been integral in recent developments of the hybrid twin screw extrusion and electrospinning and hybrid twin screw extrusion and spiral winding technologies to especially fabricate nanoparticle-incorporated nanofibers and functionally-graded extrudates, which serve as novel scaffolds in tissue engineering applications.

He is also the Director of the Highly Filled Materials Institute, which focuses on the structure, processing and properties (mixing, simulation, shaping, microstructural analysis and ultimate properties) of complex fluids and soft solids, especially polymers, gels and concentrated polymeric nanosuspensions and suspensions. The industrial applications of this research cover a wide range of industries including biomedical/tissue engineering, pharmaceutical, nanocomposites, energetics, personal care, environmental, ceramics and electronics industries. The number of contracts and grants that Prof. Kalyon has received has surpassed 130.

Prof. Kalyon has received the 2008 Research award of Society of Plastics Engineers, 2008 Thomas Baron Award in fluid-particle systems of American Institute of Chemical Engineers, the Harvey N. Davis Distinguished Teaching Assistant Professor (1987), the Henry Morton Distinguished Teaching Full Professor award (2000) the Exemplary Research Award of SIT, an Honorary M.Eng. degree (1994) and Davis Memorial award for Research Excellence (2009) from Stevens Institute of Technology, the Founder’s Award of JOCG Continuous Extrusion and Mixing Group (2004), and various fellowships including DuPont Central Research and Development Fellowship (1997), Exxon Education Foundation Fellowship (1990) and Unilever Education Fellowship (1991). He was elected Fellow of the Society of Plastics Engineers (2004) and Fellow of American Institute of Chemical Engineering (2006). He is a member of the NY Academy of Sciences, US Society of Rheology, Polymer Processing Society, British and European Societies of Rheology, American Institute of Physics, and American Society of Engineering Education.