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Modeling, Simulation, And Validation Of Process-Structure-Property Relationships In Fused Filament Fabrication, Aaron Grant

Electronic Theses and Dissertations

As additive manufacturing (AM) grows in popularity, the need for better simulation tools to predict the process-structure-property relationships of AM parts becomes ever more necessary to employ the technology in design of functional parts with varying degrees of complexity and performance requirements. Many simulation tools and techniques have been developed that aim to achieve this goal, and the main purpose of this research is to explore how well different simulation tools and modeling approaches can capture various AM-specific features such as inter-raster and end-of raster voids, and residual stresses induced by dissimilar rates of thermal expansion. Process simulation of fused …

A Systematic Approach For Waste Management In The Semiconductor Industry, Vivian Hui

Theses and Dissertations

One area that has received attention in the literature is sustainable production. This research has focused upon modifying production processes to improve sustainability. Semiconductor manufacturing has evolved into one of the most important industries in the world. However, as a new industry, semiconductor manufacturing has had far less attention in the sustainability literature as compared to more mature industries. Amongst the sustainability frameworks and methodologies that have been developed to measure the sustainability of an entity, waste is treated as an afterthought, not as the focus of the research. The literature rarely considers waste management as a component of sustainable …

Axial Compressor Based On Plastic Additive Manufacturing, Chris Phu

Mechanical Engineering Undergraduate Honors Theses

Turbomolecular pumps designed to function in very low pressures tend to be too prohibitively expensive for student researchers. On the other hand, while conventional pumps are affordable, they can’t function in extreme low pressures. An additively manufactured axial compressor however is inexpensive to manufacturer and only needs to be build up enough pressure for a conventional pump to function. After many design iterations, a final iteration that is near vacuum chamber ready has been 3D printed and tested for spin functionally. The designed axial compressor is easy to assemble and very modular. Conclusions from each of the design iterations is …

Durability Of Hybrid Large Area Additive Tooling For Vacuum Infusion Of Composites, Nathan Joseph Northrup

Theses and Dissertations

The purpose of this research was to scientifically validate potential cost-saving measures for production of large area additively manufactured tooling for vacuum infusion of composites. These cost saving measures included using a hybrid additive/subtractive manufacturing system to fabricate the mold, requiring lower capital cost and creating shorter lead times. Fiberglass reinforcement was used instead of carbon in the mold material. The validation was done by designing and fabricating a mold for a custom test artifact and analyzing the surface geometry over the course of multiple infusions until tool failure.After printing and machining, the mold required a sealer in order to …

Application Of Solar Water Heaters For Industrial Use, Lucas T. Atkins

Theses and Dissertations

Solar water heating is a technology that is mainly used for domestic water heating in residential homes. In most applications, the idea is to make a home “off the grid” in that there is no requirement for outside infrastructure or need for energy utility to provide power to this home. This falls in line with the trend of “going green” in an effort to reduce energy use, increase efficiency, or reduce emissions and other harmful byproducts.

This technology can be adapted to reduce the energy costs of industrial manufacturing plants. By eliminating the need for certain sections of a process …

Fiberglass Mat-Roll Carryover, Bryce Youngson, Aaliyah Ramos, Johann Cayaban, Tony Ledesma

Mechanical Engineering

The asphalt shingle is a type of roof shingle that uses asphalt for waterproofing. Its low cost and easy installation make it one of the most common roof covers in North America. General Aniline and Film (GAF) is one of the nation’s largest manufacturers of roofing materials and produces asphalt shingles at their Shafter, California manufacturing facility. To manufacture asphalt shingles, a base material of fiberglass passes through a series of processes that sequentially add asphalt, ceramic-coated mineral granules, and thermoplastic adhesive. The fiberglass base-material arrives at the manufacturing facility in large rolls that workers must periodically splice together in …

Runaway: A History Of Postwar New York In Four Factories, Andy Battle

Dissertations, Theses, and Capstone Projects

At midcentury, New York City was among the preeminent manufacturing centers in the United States. Within a generation, this manufacturing economy suffered an extraordinary collapse. Beginning in the 1950s, workers and their unions began to use the term “runaway” to describe factories that pulled up stakes in New York and set them back down in other climes. This dissertation explores the deindustrialization of New York City through case studies of “runaway” plants, or factories that left New York for the American South or abroad between the years 1945 and 1975.

In general, the manufacturers that remained in New York at …

Planning For Industrial Land And Industrial Jobs: An Evaluation Of New York City's Industrial Business Zone Program, Jennifer Davis

Masters Theses

In recent years, industrial preservation policies, which aim to preserve urban industrial activity and industrial employment often through the preservation of industrial land, have emerged as a flashpoint in cities across the country that have implemented these policies. While critics contend that industrial preservation policies amount to smokestack chasing in “post-industrial” cities like New York City, industrial preservationists argue that such policies help to preserve well-paying, middle-class jobs and thus represent a tool to mitigate rising income inequalities in cities. Despite considerable attention to these policies, minimal research has evaluated the effectiveness of industrial preservation policies as land use and …

Development Of An Automated Fiber Placement Process For The Fabrication Of Thermoplastic Composite Laminates, Anthony M. Sabido

Theses and Dissertations

An automated fiber placement process is desired for manufacturing variable-stiffness thermoplastic composite laminates. By developing such a composite laminate, it is possible to take advantage of the tunable performance increases that are achievable by spatially steering individual tows. In addition, using a thermoplastic polymer as the matrix material has many advantages: a high toughness, ability to employ thermoplastic joining processes that do not require adhesives, long storage life, and lacks the need to be refrigerated. This process was experimentally developed, where the effect of various process parameters on the quality of the laminate were evaluated. An experimental AFP head was …

Fluid Power Vehicle Challenge - The Incompressibles - Final Design Report, Nicholas Gholdoian, Russell Posin, David Vitt, Alex Knickerbocker, Kyle Franck, Julian Rodkiewicz

Mechanical Engineering

This report provides a comprehensive description of the research, analysis and design work that The Incompressibles have completed thus far in the senior project process. This document includes all the work that The Incompressibles have completed for the team’s Preliminary Design Review (PDR), Critical Design Review (CDR), the work leading up to the 2019 FPVC competiton and the competition results. This report includes the initial research that the team completed for the fluid power competition, first iterations of designs, final iterations of designs, manufacturing results and processes, and finally testing and results from competition. With a new design for the …

Manufacturing Efficiency Improvements On High Variation Lines, Molly J. Schultz

Honors Capstones

Motorola Solutions Inc. is a manufacturer of high quality telecommunications equipment. Their newer facility in Elgin, IL builds and assembles portable and mobile radios. Given the high variation in product mix and demand, management teams and line leads struggle to allocate the right number of workers to maximize efficiency. By creating a current state discrete event simulation model using Arena Simulation, important performance metrics were captured such as line efficiency, worker utilization, product wait times, etc. The goal is to use these performance outputs to develop an excel tool that Motorola can utilize for employee allocation.

Relationship Between The Effectiveness Of Internal Control And Financial Performance Of Manufacturing Companies In The United States: 2013-2017, Gregorius A. Pradana

Honors Capstones

This study aimed to test the relationship between the companies’ financial performances and their effectiveness of internal control (IC) or the compliance to Sarbanes-Oxley Act (SOX) Section 404 in the manufacturing industry in the United States (US) capital market. This study uses secondary data obtained from Wharton Research Data Services (WRDS) of University of Pennsylvania and EDGAR Securities and Exchange Commission database. The secondary data used from the sources are from 2013 to 2017. The data from those years were used to see the relationship between the companies’ effectiveness IC during that period and their financial performances. The result of …

Designing For Sustainable Bicycle Manufacturing, Xavier H. Arvelo Rodriguez

Theses

Currently, with the increase of people moving from one place to another, either to fulfill their daily activities or for recreation, the need has been created to produce a greater amount of means of transportation that can facilitate this action. Many people choose to use vehicles that do not help with the reduction of environmental pollution; among these, we can mention cars, buses, motorcycles, etc. The use of bicycles is predominant in countries with a developed culture and infrastructure focused on bike riding. Also, where fuel taxes are higher and people care about pollution in their surroundings.

In this project, …

High Strollers, Braeden Hammond, Morley Perrin, Reid Bartels, Juan Rodriguez

Mechanical Engineering

This report documents the final product of Jonathon’s new lightweight stroller. The Mechanical Engineering team from Cal Poly, High Strollers, began the project to create a lightweight stroller for the project sponsor, Nina Aguayo, and her son, Jonathon Aguayo, in Fall of 2018. Jonathon is diagnosed with Delayed Brain Development and Hypotonia with some characteristics of Cerebral Palsy. He has a 50lb high intensity stroller to go to and from school. Mrs. Aguayo needed a stroller that is easier to transport while still meeting all of Jonathon’s needs. The re-designed stroller will make leisurely outings for Mrs. Aguayo and Jonathon …

Universal Bike Suspension Design, Ernesto Huerta, Gregory Ryan Ritter, Chris Michael Fedor, Michael Wu

Mechanical Engineering

Cal Poly Bike Builders (CPBB) is a student club at Cal Poly helping students design and fabricate their own bicycles. Currently, club members build rigid frames and mountain bikes with only front-suspension–commonly referred to as a “hardtail”. As more students join the club, interest grows in building full-suspension mountain bikes (FSMTB). Designing and manufacturing a mountain bike rear-suspension system requires a diverse skillset and a substantial time commitment. As a result, individual efforts building FSMTB have proven unsuccessful. The scope of this project is to develop a defined method and necessary tools such that all CPBB members can efficiently build …

Improving The Accuracy Of A Finite Element Based Manufacturing Simulation: A Case Study Of Laser-Induced Bending In A Thin Metal Sheet, Joseph Johanson

Master's Theses

Finite element analysis (FEA) has become an increasingly popular tool used by researchers and professionals for comparing experimental data to theoretically expected values. Its use can prove to be an invaluable resource when analyzing or designing a system by giving the user the ability to understand the process being modeled at a much deeper level. However, finite element analysis it is still prone to generating inaccurate results if not used properly. When simulating certain physical processes, such as those found during manufacturing, the obtained results are sometimes prone to error when compared with their experimentally obtained counterparts.

The present work …

Investigation Of Design, Manufacture, Analysis, And Test Of A Composite Connecting Rod Under Compression, Thomas Juhl Rohrbach

Master's Theses

Composite materials hold great potential for the replacement of traditional materials in machines utilized on a daily basis. One such example is within an engine block assembly where massive components inherently reduce the efficiency of the system they constitute. By replacing metal elements such as connecting rods, cylinder caps, or a crank shaft with composite alternatives, a significant increase in performance may be achieved with respect to mechanical strength, thermal stability, and durability, while also reducing mass. Exploration of this technology applied to a connecting rod geometry was investigated through a combination of process development, manufacturing, numerical analysis and testing. …

Stair Climbing Hand Truck, James Mcpherson

All Undergraduate Projects

Abstract

Getting a heavy object up a flight of stairs usually requires a team of two or more people. Even with a team of people, the task is often still difficult, dangerous, and possibly insurmountable by one person. This problem is especially prevalent in for those who are moving into apartment complexes. Most apartment complexes have many buildings with two or more floors of living quarters, and elevators are often missing. This project sought to offer a solution to this problem. The solution in question; a motorized hand-truck with 2, trigonal planar pinwheels in place of the stock wheels. The …

Process Management Strategies Of Successful Small Manufacturing Companies In Massachusetts, Daniel R. Champagne

Walden Dissertations and Doctoral Studies

The manufacturing industry has been on a decline. Companies have been closed, and employees have lost their jobs. The purpose of this qualitative exploratory multiple case study was to understand how 5 small manufacturing companies in Massachusetts remained competitive. Systems theory was used to focus on process and innovation management implemented by organizational leaders. A purposeful sampling was conducted to identify 15 organizational leaders from 5 small manufacturing companies in Massachusetts. Data were collected through semistructured interviews with the 15 participants. Interviews were recorded and transcribed with NoNotes software. Data were compiled and submitted to participants to member check information. …

Closing The Manufacturing Skills Gap Through Innovative Recruiting Practices, Jeffery Combs

Walden Dissertations and Doctoral Studies

Business leaders’ recognition of the increasing shortage of skilled workers to meet industry demand is a business problem. The purpose of this multiple case study was to explore strategies that business leaders used to recruit skilled workers at 3 manufacturing facilities in South Carolina. The human capital theory was the conceptual framework used for this study. Data were collected from face-to-face interviews with 3 business leaders who demonstrated successful recruitment strategies, a focus group of 4 skilled manufacturing employees hired during the time period of 2018-2019, and a review of company documents. Data were analyzed using Yin’s 5-step process. Six …

Influential Determinants Of Internet Of Things Adoption In The U.S. Manufacturing Sector, Ronville D. Savoury

Walden Dissertations and Doctoral Studies

Manufacturers have been hesitant to adopt Internet of things (IoT) due to a lack of understanding about the innovate characteristics, technology, organizational and environmental factors related to IoT adoption and how their organizations can apply IoT correctly. This quantitative, correlational study used a combination of diffusion of innovation theory and technology–organization–environment framework as the foundation to examine if a relationship exists between relative advantage, complexity, compatibility, technology readiness, top management support, firm size, competitive pressure, and regulatory support and IT leaders' intent to adopt IoT in U.S. manufacturing organizations. A sample of 168 information technology (IT) leaders from the U.S. …

Developing A Commercial Product Using A Consumer Grade 3d Printer, Calvin Smith

All Graduate Theses, Dissertations, and Other Capstone Projects

The development of affordable, quality, consumer grade 3D printers has allowed entrepreneurs to develop new products and start small businesses. As the print quality of consumer grade printers has improved entrepreneurs have been able to develop consumer quality products without the traditional expense of mass manufacturing. This change from mass manufacturing to small scale and custom production has allowed for the growth of small businesses. Websites such as www.etsy.com show hundreds of small businesses based on 3D printing, these businesses showcase thousands of products ranging from useful household items to cosplay. This thesis covers the process of a small business …

Manufacturing In Australia – An Explorative Investigation Of Innovation Capability Enhancements Using Value Stream Thinking, Brogan Rylands

University of Wollongong Thesis Collection 2017+

Supply chains and supply chain management continue to increase in importance, with research showing that it is supply chains that compete today, rather than individual businesses (Christopher, 2011). Supply chain management in the Australian manufacturing industry is of particular importance due to the challenges and changes being faced by manufacturing. This includes but is not limited to, declining employment figures and the decreasing percentage of gross domestic product (GDP) attributed to manufacturing, the recent closures, downsizing and offshoring of manufacturing, including the closure of automotive production plants, and downsizing of a major employer and steel manufacturer which is integral to …