Engineering Commons^™

Capstone Review: Filament Unit Multiplexing Engine, Gal Cohen

University Honors Theses

The Filament Unit Multiplexing Engine (FUME) is a Mechanical Engineering capstone project sponsored by Portland State University's Electronic Prototyping Lab (EPL). The project addresses the need for an automated system to manage 3D printing operations. The current manual process of selecting and routing a spool of filament to one of the available 3D printers is labor-intensive and limits the efficiency of the lab’s 3D printing farm. FUME aims to create a custom solution tailored for a multi-user, multi-spool, and multi-printer environment. The designed system includes key components: a spool holder, an engine, a track and shuttle system, and a funnel. …

The Effect Of Extended Saltwater Absorption And Uv Cure On The Compressive Properties Of Msla 3d-Printed Photopolymer Resin Samples With Printing Variations, Suzanne Dixon

Theses and Dissertations

Liquid Crystal Display (LCD) 3D printers, also known as Masked Stereolithography Apparatus (MSLA), is a type of vat polymerization printing technique that cures liquid resin into a solid object. This technique is relatively new. Consequently, there is a shortage of detailed research on the impact of long-term environmental exposure on the MSLA-printed materials. The research within this document informs engineers and scientists of resin compressive properties after extended exposure to saltwater and ultraviolet (UV) light. Saltwater absorption of the material was analyzed at atmospheric pressure, 30-psi, 60-psi, and 90-psi; the samples reached saturation in saltwater after 56 days. The variation …

Research On 3d Printing Resin Exposure Properties And Its Application On Centrifugal Microfluidic Platform Based On Fluorescence Detection, Zheng Qiao

LSU Doctoral Dissertations

This dissertation encapsulates significant advancements in the field of SLA 3D printing and centrifugal microfluidics. Central to the research is the development of a novel mathematical model for predicting trapped resin thickness in SLA 3D printing, a groundbreaking contribution that addresses a critical aspect of printing intricate structures. This model, the first to establish a mathematical relationship for resin thickness, is rooted in a comprehensive study of the resin curing process. The research leverages the concept of 'critical dosage' for resin curing, leading to a more refined and theoretically grounded approach for calculating curing thickness. Experimentation further validates the model, …

Directional Dependent Fracture Characteristics Of 3d Printed Mechanical Metamaterials, Thomas Draper

Dissertations, Master's Theses and Master's Reports

Structural metamaterials, such as lattice metamaterials, are engineered cellular structures designed to achieve properties not achievable by natural materials. They enable mechanical properties unattainable by homogeneous solid materials and offer optimal properties for these materials tunable for specific applications in industries such as automotive, medical, and aerospace. Recent findings have revealed unique tunable mechanical properties such as negative Poisson's ratio, high strength-to-weight ratio, anisotropic stiffness, and much more. While the elastic and wave propogation properties of many lattice metamaterials are well investigated, the fracture properties are not well explored. However, their low fracture toughness is a bottleneck for their use …

Materials Testing For Large Format 3d Printing, William Jenkins

Williams Honors College, Honors Research Projects

An ABS Carbon Fiber blend was printed into single walled hexagons at a variety of settings on a Cincinnati BAAM large format 3D printer. These hexagons were then cut down into sheets and had tensile and flexural test samples cut out of them, in order for materials testing to be performed. Tensile strength, tensile strain, young’s modulus, flexural strength, deflection and elastic modulus were all determined. A desktop CNC machine and a planer were purchased for the manufacturing of these samples, and an efficient cutting procedure was designed and optimized. After all data collection concluded, this data was thoroughly analyzed, …

Advances In Cellulose Nanomaterial-Based Foams For Environmental Applications, Md Musfiqur Rahman

Electronic Theses and Dissertations

The use of metal-oxide nanoparticles adsorbents is limited to fixed-bed columns in industrial-scale water treatment applications. This limitation is commonly attributed to the tendency of nanoparticles to aggregate, the use of non-sustainable and inefficient polymeric resins as supporting materials, or a lack of adsorption capacity. Foams and aerogels derived from cellulose nanomaterials have unique characteristics, such as high porosity and low density, which enables their use in a variety of environmental applications, including water treatment. However, the overall use of cellulose nanomaterial-based foams in various environmental sectors is limited due to the high cost of production associated with time- and …

Modeling, Control, And Hardware Development Of A Thrust-Vector Coaxial Uav, Andrew North

Doctoral Dissertations and Master's Theses

This thesis introduces a unique thrust vector coaxial unmanned aerial vehicle (UAV) configuration and presents a comprehensive investigation encompassing dynamics modeling, hardware design, and controller development. Using the Newton-Euler method, a dynamic model for the UAV is derived to gain in-depth insights into its fundamental flight characteristics. A simple thrust model is formulated and modified by comparing it with data obtained from vehicle testing. The feasibility of manufacturing such a vehicle is assessed through the development of a hardware prototype. Finally, a linear state feedback controller is designed and evaluated using the non-linear dynamics model. The results demonstrate successful validation …

3d Printed Aircraft, Matthew Nagy, Charles D'Amico, Alexis Salgado Medina

Mechanical Engineering

This project is to design, build, and test a 3D-printable aircraft. The goal is to create a final design that will be able to fly for the longest duration possible, around 20 seconds. To determine the correct preliminary design and manufacturing process for a 3D printed RC aircraft, an analysis of multiple design options and manufacturing materials was performed. This allowed for a variety of choices for aircraft type, airfoil design, structure, among other topics to be narrowed down to the most promising option. It has been found that the aircraft will follow a design similar to industry motor-gliders, with …

Feasibility Of Thermoplastic Extrusion Welding As A Joining Method For Vacuum-Assisted Additively Manufactured Tooling, Chase C. Flaherty

Electronic Theses and Dissertations

In recent years, additive manufacturing (AM) has been successfully utilized for the production of large-scale composite tooling. Within these endeavors, however, limited research has focused on joining methods between printed sections. This work evaluates the feasibility of thermoplastic extrusion welding as a joining method for additively manufactured tooling structures. This joining method was assessed based on industry specifications of conventional thermoset tooling for wind blade manufacturing utilizing the vacuum-assisted resin transfer molding (VARTM) process. The specifications include requirements for the mechanical strength, vacuum integrity, roughness, and hardness of the tool surface. The feasibility of this welded polymer joint was demonstrated …

Part Design Geometry-Driven Toolpath Optimization For Additive Manufacturing Energy Sustainability Improvement, David Kolawole Somade

Graduate Research Theses & Dissertations

One of the most promising new manufacturing technologies in the past three decades isadditive manufacturing (AM), also commonly known as three-dimensional (3D) printing or rapid prototyping. The energy consumption problem in AM can be significant when it is adopted at the industrial scale or used under resource-restricted conditions. The energy consumption of an AM process is influenced by several factors including bed heating, filament extrusion, material infill, component cooling, etc. All these factors are further determined by the equipment and the toolpath for a specific printing task. Build orientation and tool-path direction are frequently used to optimize part and process …

Thermoplastics 3d Printing Using Fused Deposition Modeling On Fabrics, Maxwell M. Blais

Electronic Theses and Dissertations

The creation of objects with integrated flexibility is desired and this can be achieved by additive manufacturing on fabric. We propose to use a textile fabric as a flexible joint and create to create an entire object with smaller parts called segments. Such a novel technique will bring integrated flexibility and folded assemblies using extrusion based additive manufacturing machines. The proposed process allows segments to be created flat one at a time on a continuous fabric, which will be suitable for flat to folded assemblies and eliminate size limitations of the 3D printer. Techniques considering object segmentation were used to …

A Machine Learning Approach To Robotic Additive Manufacturing Of Uv-Curable Polymers Using Direct Ink Writing, Luis A. Velazquez

LSU Master's Theses

This thesis presents the design and implementation of a robotic additive manufacturing system that uses ultraviolet (UV)-curable thermoset polymers. Its design considers future applications involving free-standing 3D printing by means of partial UV curing and the fabrication of samples that are reinforced with fillers or fibers to manufacture complex-shape objects.

The proposed setup integrates a custom-built extruder with a UR5e collaborative manipulator. The capabilities of the system were demonstrated using Anycubic resin formulations containing fumed silica (FS) at varying weight fractions from 2.8 to 8 wt%. To fully cure the specimens after fabrication, a UV chamber was used. Then, measurements …

Characterization Of 3d Printed Parts Containing Integrated Functionality Via Ultrasonically Embedded Wires, David Abraham Sepulveda

Open Access Theses & Dissertations

Material extrusion additive manufacturing has been widely adopted because it offers freedom of design, which allows complex geometry fabrication, and rapid prototyping. Interest in producing components with integrated functionality allowed forms of hybrid manufacturing to be developed such as the Multi3D system. This system produces parts with embedded components by combining additive, subtractive, soldering, dispensing, and embedding techniques. However, this involves pausing the printing process (which takes place in a controlled environment) and exposing it to ambient temperature where embedding takes places. In this research, the effect of embedding parts with 24 AWG copper for improved functionality was quantified mechanically. …

Expanded-Range Venturi Flow Meter: Development And Testing Of A 3d-Printed Flow Meter And Solid-State Valve Concept, Joseph M. Pomo

Mechanical Engineering ETDs

In this thesis, I document the design, testing and performance of a novel Expanded-Range Venturi Flow Meter (ERVFM) concept. The ERVFM combines two, parallel-configured Venturi Flow Meters (VFM) with a Solid-State Selector Valve (SSSV). The goal was to create a reliable, high-turndown ratio flow meter which directs the fluid to either Venturi tube using the inherent pressure drop of the SSSV, and without moving parts. I constructed a pumped-fluid loop test-setup and quantified the ERVFM’s performance through pressure loss and mass flow rate measurements. In addition, I used python to develop models to assist in prototype design and data-processing. My …

Development And Evaluation Of Modeling Approaches For Extrusion-Based Additive Manufacturing Of Thermoplastics, Christopher C. Bock

Electronic Theses and Dissertations

This work focuses on evaluating different modeling approaches and model parameters for thermoplastic AM, with the goal of informing more efficient and effective modeling approaches. First, different modeling approaches were tested and compared to experiments. From this it was found that all three of the modeling approaches provide comparable results and provide similar results to experiments. Then one of the modeling approaches was tested on large scale geometries, and it was found that the model results matched experiments closely. Then the effect of different material properties was evaluated, this was done by performing a fractional factorial design of experiments where …

Enhancing Stability Of High-Nickel Cathodes For Lithium-Ion Batteries Through Additive Manufacturing Of Cathode Structure, Matthew Sullivan

Mechanical Engineering Undergraduate Honors Theses

Lithium-ion batteries (LIBs) are currently the best method to store electrical energy for use in portable electronics and electronic vehicles. New cathode materials for LIBs are consistently studied and researched, but few are as promising and attainable as nickel-rich transition metal oxides such as LiNi1-x-yMnxCoyO2 (NMC). NMC materials exist with many different mass ratios, but higher nickel content materials provide higher energy density. With this increase in capacity comes a sacrifice with cyclability, as high-nickel NMC variants are prone to structure collapse, transition metal dissolution, and cracks due to volume change. In this report, mechanical modification of the electrode by …

Carbon Fiber Coil Spring Characterization And Manufacturing, Cooper Madrazo

UNLV Theses, Dissertations, Professional Papers, and Capstones

Helical coil springs are used in many mechanical design applications including industrial machines, devices, and vehicle suspension systems. It is desirable to minimize the weight of vehicle suspension systems as this can improve performance and handling. Most vehicle suspension coil springs are made from solid steel alloys or other metallic materials. Significant weight savings could be achieved if the metallic material were replaced by high performance fiber reinforced polymer composites. However, the coil spring geometry is a difficult manufacturing challenge for composite materials. The goal of this thesis was to investigate efficient and low-cost manufacturing methods to produce light-weight polymer …

Utilization Of Resin-Based Additive Manufacturing For Investment Casting, Matthew Frost, Isaiah Hong

Mechanical Engineering

Dr. Xuan Wang, an Industrial & Manufacturing Engineering (IME) professor at California Polytechnic State University, San Luis Obispo, has sponsored the resin-based 3D printing investment cast senior project. The objective of the project was to thoroughly research the process and document the findings of using a resin-based 3D printed part as the pattern for investment casting. While this manufacturing process is not necessarily a new idea, the lack of technical research and documentation limits its ability to be reproducible. The research portion of the senior project included analyzing the limitations to the printing/casting manufacturing process. Measurements of part thicknesses, hole …

Multi-Objective Optimization On Dimensional Accuracy, Edge And Surface Quality Of 3d-Printed Parts By Fused Deposition Modelling, Islam Hamdy Salem

Theses and Dissertations

Fused Deposition Modelling (FDM) is one of most common additive manufacturing (AM) techniques used in manufacturing field. It has been increasingly used because of its low cost and simplicity. Although FDM can save time through eliminating pre-processing tooling-up to produce the end-user product, still a better final product quality, like mechanical properties, dimensional accuracy and surface finish, is needed. This thesis addresses the maximization of involved printing parameters in one reliable model. Hence, a wider investigation is conducted in this research via experimental work in order to obtain a comprehensive model that involves and relates more parameters in a single …

Rc Baja, Cam Jamison

All Undergraduate Projects

To satisfy the Mechanical Engineering Technology program requirements a senior project was accomplished with an RC car build. An RC car was designed, manufactured, and tested to meet all requirements set forth by American Society of Mechanical Engineers (ASME) RC Baja competition. A two-person team was assembled to build the RC Car. Teammate Paul Lervick was responsible for the suspension and chassis components and the other was responsible for the drivetrain and steering components. During the fall quarter drawings and general designs were created. Many different RC cars and motorized vehicles were referenced when initially coming up with aesthetic ideas. …

Ljm Rc Baja Vehicle Project Chassis And Suspension, Paul Lervick

All Undergraduate Projects

An RC car was designed, analyzed, and manufactured to compete in the ASME RC Baja competition. The focus was to optimize the suspension and chassis components to minimize the weight while maintaining the structural strength of the components which would intern supplement the overall speed and stability of the vehicle. Other components were the responsibility of the teammate Cam Jamison. To complete this there was extensive research done on Traxxas RC cars and what went into making a high-performing vehicle that would compete well in the 3 races that comprise the competition (slalom, sprint, and obstacle course). There were then …

Design And Fabrication Of A Polymer Fdm Printer Capable Of Build Parameter Monitoring And In-Sit Geometric Monitoring Via Photogrammetry, Travis Roberts

All Theses

Additive manufacturing, or 3D printing, is a complex process that creates free-form geometric objects by sequentially placing material in a location to construct an object, usually as a layer-by-layer process. One of the most widespread methods is Fused Deposition Modeling (FDM). FDM is used in many of the consumer-grade polymer 3D printers available today. While consumer grade machines are cheap and plentiful, they lack many of the features desired in a machine used for research purposes and are often closed-source platforms. Commercial-grade models are more expensive and are also usually closed-source platforms that do not offer flexibility for modifications often …

Med-Drop Pill Dispenser, Cole Pike, Taylor Morris, Christopher Bruni, Jose Gomez

Mechanical Engineering

Veterans’ Affairs home care nurses currently spend anywhere from thirty minutes to two hours filling out monthly prescriptions one pill at a time to veterans who are unable to leave their homes. The goal of this project was to create an easy-to-use device that could be left at a patient’s home that nurses could use to quickly and accurately dispense medication into the patient’s monthly pill box.

Multiscale And Multimaterial 3d Printing: Impact Of Feedstock Properties And Processing Parameters On Printed Parts, Kazi Md Masum Billah

Open Access Theses & Dissertations

Material extrusion additive manufacturing (AM) technology is one of the most commonly used technology to fabricate functional prototypes and end-use application parts with custom design. The evolution of the extrusion technology led this particular AM process to grow in many aspects such as new materials development, new design thinking, fabrication of parts in multiscale length, and manufacturing of monolithic parts with multiple functionalities. The research presented in this Dissertation results in the creation of knowledge in material extrusion AM technology with the length scale of production-grade to large-scale 3D printing machine those were used to enable the fabrication of multimaterial …

Design Of A Cable-Driven Manipulator For Large-Scale Additive Manufacturing, Phillip Chesser

Masters Theses

Additive manufacturing of concrete is a growing field of research, yet current motion platforms do not offer viable routes towards large scale deployable systems. This thesis presents the design and analysis of a novel cable-driven robot for use in large scale additive manufacturing. The system developed, termed SkyBAAM, is designed to be easily deployable to a construction site for on-site additive manufacturing of buildings and other large structures. The design philosophy behind this system is presented. Analysis of this system first explores the kinematics, and stiffness as a function of cable tension. Analysis of the workspace and singularities is also …

Senior Design Capstone: Using An Engineering Design Process To Create A Sawzall Wobble Fixture For Milwaukee Tools, Tyler Moore

Honors Theses

The overall objective of this design project was to successfully design a fixture to expedite the repairs of Sawzalls at the Milwaukee Tools repairs facility in Greenwood, Mississippi. This project was executed in accordance with guidelines set forth by the Senior Capstone Design class at the University of Mississippi as well as the quality engineers sponsoring the project at Milwaukee Tools. The fixture was created utilizing an engineering design process with the goal of allowing technicians to press two Sawzall wobbles onto an angled Sawzall wobble shaft using an arbor press with just one press. By beginning with a straightforward …

Dynamic Loading Directed Neural Stem Cell Differentiation, Abdullah Revaha Akdemir

USF Tampa Graduate Theses and Dissertations

Spinal cord injuries (SCI) are among the biggest challenges for medical and engineering fields in the modern era. Many people experience various accidents every year that cause major irreversible trauma in the spinal cord. Damaged neural cells caused by SCI cannot be regenerated, and patients have to live with pain, spasms, or loss of movement. Stem cell differentiation can be a potential solution to generate enough neurol cells in vitro to apply at the defective region. In this research, the impact of dynamic mechanical stimulation on the differentiation of PC-12 cell lines towards neurol cells was studied. Models to apply …

Printing Parameter Determination And Characterization Of Additively Manufactured Kovar Steel, Will Macgreggor Davidson

Mechanical Engineering ETDs

Kovar (ASTM F15, UNS K94610) steel has many applications across Sandia National Laboratories but is best known within academia and industry for its glass-to-metal and glass-to-ceramic hermetic sealing capabilities. Successful printing parameters for a Renishaw AM400 to additively manufacture artifacts from Kovar steel powder have been determined. The printed test artifacts have been studied for ultimate tensile strength, density, surface roughness, hardness, bulk composition, and impact toughness. Longer throughput measurements such as porosity, coefficient of thermal expansion, and grain structure studies have been established for future delivery to the research team. Yet another delivery from this thesis research is a …

Design And Testing Of A Feed-Forward Control System For Deployable Vortex Generators Dependent On Angle Of Attack, Solomon B. Whitmire, Christopher J. Chapanar, Kirklin M. Anderson, Nickalus R. Amon, Daniel W. Chech

Williams Honors College, Honors Research Projects

A vortex generator (VG hereafter) is a common feature of an aircraft wing that disturbs the flow on the leading edge of the wing, thus energizing the boundary layer and reducing flow separation. For an aircraft experiencing flow separation, VGs can increase the lift-to-drag ratio of the wing and prevent stall; however, if flow separation isn’t an issue, the unnecessary frontal area of the VGs has the potential to produce parasitic drag. This study seeks to determine whether the use of a deployment system can improve the performance of VG’s by raising or lowering them depending on the angle of …

Design For Additive Manufacturing (3d Printing), Michael O'Donnell, Michael J. Levy

Williams Honors College, Honors Research Projects

The goal of this project is to study the performance of a 3D printed mechanical part subjected to topology optimization. A part that is somewhat complex in its load bearing and geometry will be selected. That part will then be designed, finite element analysis will be performed on it to optimize its topology, and then it will be 3D printed and tested. The goal of topology optimization is to either save material cost and/or part weight due to the ability of 3D printing to manufacture parts with complex and obscure geometry.