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Hitch Cart “Landing Gear”, Rebekah White, Jose Raygoza, Randy Hernandez, Brandon Leon

Mechanical Engineering

This report aims to allow our sponsor, to review our design process of the Hitch Cart Landing Gear Prototype. In the design overview section of this report, we discuss the primary design modifications we made to the wheel mechanism of the existing hitch cart prototype, including the addition of the ACME screws and the folding brackets. This allows our sponsor to see the intended improvements made to the past prototype and understand the primary goal of our project. Then, in the implementation section, we cover the entire manufacturing process to allow our sponsor to understand what manufacturing steps must be …

Formula Integrated Monocoque Development, Hayden Wagner, Aaron Fang, Elijah Schulz, Carson Smith

Mechanical Engineering

Every year the Cal Poly Racing FSAE club set out to create two separate race cars to compete in the upcoming formula combustion and formula electric competitions. Both the combustion and electric formula cars operated on the same vehicle platform with the powertrain systems being the main difference between the two cars. Cal Poly Racing FSAE is the only school in California to run a full carbon fiber monocoque chassis, with each chassis design operating on a roughly four year design cycle. A new FSAE senior project team has set out to improve upon the previous chassis design as the …

Autolacing The Dml, Harrison Hong, Chanh Tu Derek Lam, Candice Espitia, Paolo Navarro

Mechanical Engineering

The design challenge present is the design of a system to efficiently speed up the lacing of the dry mat loop (DML), part of the GAF production line. For this year, the scope of the project focuses on research and creating a proof of concept for the mechanism responsible for moving the mat within the DML. Compiled research focuses on competitor solutions, material properties, and possible mover mechanisms to be integrated into the major design. Competitor solutions provide an idea of raw material manipulation options. Material properties and possible mover mechanisms provide the foundation for ideation and concept prototyping. The …

Facility Thermal Balance And Transport, Giovanni V. Minnite, Silas O R Goldfarb, Cole J. Houston, Dominique Aguilera, Cole M. Silva

Mechanical Engineering

This Final Design Review (FDR) report outlines the senior design project completed by a team of five mechanical engineering students at California Polytechnic State University, San Luis Obispo for Senior Industrial Engineer, Mr. Tom Bass, of Entegris, Inc. The team developed an innovative system to address the issue of ice accumulation on cryogenic vaporizers at the Entegris facility. Ice buildup, caused by the extremely low temperatures of the cryogenic fluid, reduces the efficiency of vaporizers and places additional stress on the system. To combat this, the team designed and constructed a prototype that utilizes a thermal transport loop to transfer …

Animatronic Lego Girl Scout, Jared Sinasohn, Filippo Maresca-Denini, Jacob Lantin, Sean Nakashimo

Mechanical Engineering

This Final Design Review Report provides a comprehensive overview of our Senior Design Project, with a focus on the testing, modifications, and final design of our animatronic robot. The primary objective was to ensure the robot met the sponsor's requirements through rigorous final testing and targeted enhancements. Significant updates include enabling the robot to display the Girl Scout salute, wave, and give a low five. Throughout the design process, critical milestones were achieved, such as the complete assembly of the robot frame and securing it onto the platform, allowing the robot to perform its programmed actions effectively. The implementation of …

Improved Combustion Liner Seal​, Christopher J. Ng, Max Case, Mason Jones, Jacob Matties

Mechanical Engineering

The project's objective was to develop a mechanical seal to seal the gap between the combustion liner and the stage one nozzle of a Solar Turbines turbine. A metal axial E-seal was selected as the sealing mechanism. Hand calculations and finite element analysis were conducted to confirm the designs compatibility with existing turbine components and the operational environment. A small-scale test rig was built to confirm the remaining design specifications. Results from this test rig indicated the design met all specifications except leak rate. Causes for this low performance were identified as manufacturing issues and some were addressed, resulting in …

Controls And Autonomy Research Testbed (C.A.R.T.), Sydney S. Ulvick, Joseph Micheal Sleeman, Mason Snyder, Lucas Grizzle, Aidan Schwing

Mechanical Engineering

Our team, Controls and Autonomy Research Testbed (CART) team modified and built upon the work of the Battery-Powered Autonomous Cart conversiON (BACON) senior project. BACON was the project before ours, with the goal of developing an autonomous vehicle platform for use as a test platform by the Mechanical Engineering department at California Polytechnic State University (Cal Poly). The project's scope included a redesign of the braking and steering systems, a ground-up design of the e-stop and acceleration systems, and integration with an embedded controller. This project was proposed by Professor Birdsong, who desires a platform for autonomous vehicle control system …

Robot Rodeo, Daniel Rickers, Tyler Vaughn, Vinayak Sharath, Berent Baysal, Promit Das Gupta

Mechanical Engineering

This document outlines the Final Design Review (FDR) for an autonomous robot developed in response to the Naval Surface Warfare Center (NSWC) Ship Maintenance Robot Rodeo Challenge. Through extensive analysis, we selected a design concept, built a verification prototype, and tested the prototype in the NSWC Robot Rodeo Competition. The design overview portion of this report will present the details of our design while explaining how it will function. Next, is our implementation section, which provides evidence about our procurement, manufacturing, and assembly of our product. Our design verification follows and explains the tests that we conducted on the robot …

F56: Rocket Thrust Vector Control, Ethan Douglas Anderson, Yiming Trent Jia, Sahil Sampat

Mechanical Engineering

This Final Design Review (FDR) report compiles relevant information regarding the Rocket Thrust Vector Control senior project as sponsored by Ethan Anderson from Cal Poly Space Systems (CPSS). Documented in this report is our progress from the months following our Critical Design Review (CDR) completion. This consists of a brief overview of the design our thrust vector control (TVC) system and its subassemblies with design changes noted, a thorough walkthrough of our procurement, manufacturing, and assembly process for creating our verification prototype (including software), a breakdown of how we verified each of our specifications through inspection and testing and the …

Ross Dam Micro Hydro Project, Marirose Evenden, Tyler Reents, Elena Ryan, Tevan Kim

Mechanical Engineering

The Ross Dam and reservoir in Angels Camp needs a reliable power source for powering its SCADA system which monitors its water level and flow rate. Currently, the existing hydro power supply is very unreliable and needs to be replaced with a micro hydro generator system that can consistently produce power to charge the onsite batteries. This paper details the design and implementation of a micro hydro Pelton wheel replacement system designed by our senior project team.

Outlined in this report is our design overview of the system and how our project will redesign and optimize the use of the …

Quarter Car Suspension Model, Jack Miller, Alexander Eckhardt, Jonathan Lam, Max Gardenswartz

Mechanical Engineering

Dr. Porumamilla, Professor of Mechanical Engineering at Cal Poly, needs a way to demonstrate the concept of base excitation to the mechanical engineering students in the Mechanical Vibrations (ME 318) Lab. A mass-spring-damper model represented by a quarter-car suspension has been selected to represent this concept. A team of four students was assigned to design such a model as a senior design project. This document will explain the testing procedures, how were the results, and if they achieved our requirements. Furthermore, the document will explain how we assemble our product and manufacturing steps. Additionally, Critical Design Report (CDR) design changes …

Scitechatorium Exhibit, Adam Khan, Cole Busch, Logan Femling, Alan Onuma

Mechanical Engineering

This document outlines the final stages of development and analysis of our interactive children’s exhibit for the Bellevue-Santa Fe Charter School’s SciTechatorium. We will showcase the final form of our ball and track display, giving a detailed look at each component and subsystem.

To describe how our final prototype will be built we have included a detailed manufacturing summary for our design. Our models have been designed with manufacturability in mind, and we have outlined which processes were used to produce all our parts.

There are also detailed descriptions of testing that were conducted to verify the performance of the …

F21 - Variable Damper, Harrison Pomerantz, Anthony Mendoza, Owen Wilks

Mechanical Engineering

This document outlines the final design phase for the Solar Turbines Variable Damper project, aiming to enhance the safety and serviceability of gas turbines enclosure ventilation system. The primary focus of this project is to address the challenge of maintaining optimal internal pressure within the gas generator enclosures while enabling remote control of the damper position.

In this report, the full system design is described in detail. Then, the part procurement, manufacturing, and assembly of the variable damper and test stand is provided to outline the steps and processes taken to complete the final prototype. After discussing the final prototype, …

Port Adapter For Unported Pressure Sensors, Peter Kristjaan Tomson, Yasser Fahad Aldaoud, Terak Benjamin Hornik

Mechanical Engineering

Boundary layer research is an exciting and ever-changing field in fluid mechanics; thus, the need for high-quality empirical data is ever-growing in importance. Dr. Westphal, a professor at California Polytechnic State University, San Luis Obispo’s (Cal Poly) Mechanical Engineering Department in conjunction with Northrup Grumman is conducting just such research. Dr. Westphal has elected to make the change to pressure sensors that do not come with a built-in port to connect to pitot-static tubes. This necessitates a solution to adapt an unported pressure sensor to his testing apparatus which requires a tubed connection. This document outlines the Final Design Review …

Focused Led Sintering, Dylan Defazio, Nilav Maulik, Branden Majors, Michael Fontillas

Mechanical Engineering

This report provides a detailed overview of the final design of our light-emitting diode (LED) focusing system. Our system incorporates a converging lens and a specially designed "glass funnel," which acts as a thick fiber optic that narrows the light to a fine point through internal reflection. The glass components of our system are precisely housed in a part made using advanced computer-numeric controlled (CNC) Mill and CNC Lathe manufacturing processes. This ensures high precision and durability of the overall system. Our LED focusing system is designed with a 60-watt stage light. The decision to use a glass funnel as …

Cal Poly Battle Bot, Jyotaaver S. Nirula, Johnathan W. Waldmire, Andrew D. Peterson, Nathaniel Ab Davis

Mechanical Engineering

This senior project endeavored to design, construct, and optimize a 120lb robot combatant tailored for the competitive arena of combat robotics. The project is a collaborative effort between mechanical, computer, and electrical engineering students at Cal Poly, combining diverse expertise to achieve a unified goal. Our competition, RoboGames, was in April of this year in Northern California.

The mechanical engineering team assumed primary responsibility for the physical components of the battle bot, focusing on three pivotal components: a robust drivetrain, armor, and a highperformance vertical spinner. These elements constitute the foundation of the battle bot's offensive and defensive capabilities, crucial …

Northrop Grumman Collaboration Project, Dominic De La Mora, Michael C. Hartley, Allison Lee, Chase Pietro, Seamus Robinson

Mechanical Engineering

The Northrop Grumman Collaboration project, emphasizing the Mechanical Engineering Senior Design team, is focusing on developing the Fire Response Aircraft (FRA) for the autonomous search and rescue system. The goal of this aircraft is to scan a predefined flight path and locate a simulated fire in which other vehicles will respond to the area. This Final Design Review report highlights the overall design, manufacturing, testing, and discussion of the final prototype. Any new changes to the final design since the Critical Design Review report are noted and include appropriate justification. The manufacturing processes for each component are outlined in detail …

Rover On A Chip (Roach) Debris Utility & Solar Shell Technology (Dusst), Joshua Aaron Tuttobene, Jacquelyn Rose Banh, Nathan Christopher Chapman, Tanner Casey Wells

Mechanical Engineering

The Rover on A Chip project’s Debris Utility and Solar Shell Technology team’s final design is outlined in this document. Starting with the design of our system, this document highlights important progress made since the Critical Design Review and fully describes our final design and verification of our final prototype. We then justify these design choices by testing multiple functionalities and conditions to ensure they will meet all of our specifications. Next, we describe in detail our procurement manufacturing method for the project. Lastly, we wrap up by discussing recommendations and the next steps for the project moving forward.

Since …

3d-Printed Remote Controlled Aircraft, Sebastian Bessoudo, Jose Ramirez, Manny Ruiz, Andrew Edwards

Mechanical Engineering

The Senior Project for the 3D Printed Aircraft presents a compelling challenge to the team: design and fabricate an aircraft for the Cal State LA 3D-Printed Fixed-Wing Aircraft Competition, comprising three distinct events: Flight, Design, and Simulation. The objective of the flight competition is to achieve the longest flight duration, while the design event emphasizes innovation and originality. In the Simulation contest, our aircraft's CAD model undergoes Computational Fluid Dynamics analysis to assess its aerodynamic performance. These competitions are slated for May 2024.

While building the aircraft has its limitations due to the source of our construction being only 3D …

Sim Racing Pedal Assembly, Ben Wold, Owen Clobes, Angel Perales, Mike Mcmasters

Mechanical Engineering

At an increasing rate, professional and amateur race car drivers are utilizing simulated racing as a training aid and even a substitute for real-life car racing. The team’s objective in this project was to create a sim racing pedal assembly aimed at filling this gap in the industry, aided by Justin Jang of Data Driven Racing LLC. The project resulted in a fully operational throttle and brake pedal which incorporated dual spring brake pedal resistance system and radial displacement sensor in the throttle. By collecting real race car data and selecting and testing spring setups based on this real data, …

Automated Expanding Fireplace, Fermin Moreno, Eduardo Hernandez, Wilbert Quiterio, Ben Hoefer

Mechanical Engineering

The Final Design Review (FDR) encompasses information regarding the final design verification prototype (FVP), manufacturing, testing, and future recommendations for the Expanding Fireplace Senior Project sponsored by the SLO Civic Ballet. The project aims to create the frame of an expanding fireplace set piece for The Nutcracker production at the Cal Poly Performing Arts Center in December 2024. The current set piece being used has unfavorable features that will be addressed with the new design. The current set piece being used has unfavorable features that have been addressed with the new design we have developed. Our sponsors have proposed several …

Hydropower Collegiate Competition, Neel Bhargava, Connor Stoll, Cameron Brosnahan, Tobias Coughlan

Mechanical Engineering

As part of our team’s participation in the 2024 Hydropower Collegiate Competition, our team constructed and iterated a small-scale Kaplan turbine using a custom-designed test rig and dynamometer. While our model was vastly simplified from what is used in the real world, the process gave us exposure to design procedures and hydrological techniques for turbine design. Crucially, we learned that while analytical models and theory are valid tools as starting points, the use of computational and experimental models is key to developing sound designs.

In the end, our group was able to produce a Kaplan turbine with a peak efficiency …

Miniature Train Engine, Jason Patrick Lacson Del Castillo, Renato Andrew Dilauro, Sophia Theresa Tiu, Robert John Pallares Iii

Mechanical Engineering

This report details the redesign of the Mini Train Prop for the SLO Civic Ballet’s The Nutcracker, aiming to create a lighter, more user-friendly, and easily maneuverable train. The Final Design Review (FDR) includes the design process, manufacturing plan, and justifications for decisions made. Key improvements are reducing the train's weight, automating the fake wheels, and enhancing maneuverability with a neutral pin and lever system. In this report we detail the significant changes since the Critical Design Review (CDR). The implementation covers procurement, manufacturing, and assembly, while design verification ensures compliance with cost, weight, turn radius, and structural integrity specifications. …

Supermileage Competition: Vehicle Chassis, Enrico Miguel Sangalang, Walter Oppelt, Adam Ponce, Vincent Corella

Mechanical Engineering

The Supermileage Urban Concept Vehicle Chassis Project was proposed by the Cal Poly Supermileage club. The goal of this project is to deliver a fully assembled vehicle chassis by the end of the 2023-2024 school year to be used by the club in the 2025 Shell Eco-Marathon competition. The competition requires a four-wheeled vehicle to comply with various requirements outlined in the Shell Eco-Marathon rulebook, such as dimensions and some safety requirements. The team selected a backbone-style chassis as the design direction. This design consists of a main structural beam that supports all other chassis and vehicle components. This main …

Rapid Composter, Cate Seay, Clarisbet De Jesus, Lesley Milena Estrada, Reese Dennett

Mechanical Engineering

This Final Design Review documents the efforts of a team of mechanical engineering students from California Polytechnic State University, San Luis Obispo as they work towards completing their assigned senior design project. This team was tasked with designing and developing an onsite rapid composter for the Girl Scouts of California’s Central Coast. The selected design concept that will be explained focuses on creating a composter that is child-safe, portable, weatherproof, solar-powered, and requires minimal manual user input. This report will not only provide a detailed description of the chosen design but will also supply an extensive design justification. This mainly …

Team F16: Autonomous Research Plane, Andrew Sugamele, Andrew Whitacre, Nicholas Toal, Cole Bushur

Mechanical Engineering

The autonomous research plane is a remote-controlled plane used for both in-flight data collection and to explore new manufacturing methods for Design Build Fly, an engineering club on campus. The club does not have the resources or time to implement data collection for their competition plane, so we built a plane in parallel, following similar rules to mimic the work and schedule that the club would use during their season. We first did research and analysis to determine the structure of the plane, geometry of wings, sizing of the tail, and what airfoil to choose. The manufacturing process included making …

Nsf-Eri Evolution Of Liquid Sheet Edges Project: Soap Film Frame Withdrawal And Positioning Apparatus, Samir S. Patel, Sophia Young, Nicole N. Morgan

Mechanical Engineering

The experimental investigation of instabilities along retracting liquid sheet edges seeks to answer a fundamental fluid mechanics question. We’ve successfully delivered an experimental apparatus to conduct research and answer this question. This document chronicles a design overview of our apparatus, our manufacturing process, our design verification, and recommendations for future steps. The final product is a document outlining our final design (i.e., our ‘Final Design Review’ (FDR)).

Automated Expanding Christmas Tree, Ben Mosemann, Zoey Camarillo, Xiomara Medina, Will Tedone

Mechanical Engineering

The Civic Ballet of San Luis Obispo (SLO) needs a new expanding Christmas tree for their 2024 production of The Nutcracker. This Final Design Review Report outlines pertinent information regarding the Cal Poly Mechanical Engineering Senior Project of Team F14 (“D.R.E.I.D.E.L.S.”), who was tasked of designing and building the new expanding Christmas tree frame. Our team’s name, “D.R.E.I.D.E.L.S.,” stands for Design and Research of Expansion Integrated Dramaturgy Ergonomic Leveraging Systems. We thought this would be a fun, creative, and ironic name for our team.

In this report, our team will discuss how we procured the materials required and manufactured and …

Advanced Wildfire Hose Clamp, Sean King, Christopher Tokarse, Connor Buchinski, Isaac Maddox-White

Mechanical Engineering

This report describes in detail the manufacturing, assembly, and testing of our hose clamp. We start with a review of the changes we have made to our design since our last report, namely a new automatic latching system, and continue with our manufacturing and assembly processes. Then we detail our testing procedures that we created to evaluate how well our design meets user needs and discuss the results of our tests. Unfortunately, our design did not meet our residual flow rate criteria and showed excessive leaking when clamped, so we end with some discussion of the issues our design has, …

Spring Rate Measurement Of A Pneumatic Mountain Bike Tire, Joseph D. Balderama, Alexandre Kachlakev, Duncan Wyke, Luki Rosen

Mechanical Engineering

The Final Design Review (FDR) presents a comprehensive overview of the spring rate measurement project for a pneumatic mountain bike tire. This report details the project's design, its implementation, and how it met all specified requirements. It also includes a discussion of the project's findings and recommendations for future work, assuming continuation of the project. The primary goal is to develop a device that allows professional race teams or experienced mountain bike riders to parameterize tires based on their spring rate in addition to internal pressure.

Since the Critical Design Review (CDR), the design has undergone significant changes due to …