Computer-Aided Engineering and Design Commons^™

Fsae Bespoke Brake Calipers For Hub Motor Architecture, Connor William Vaughan, Liam Upton Walsh, Bradley Brian Kern

Mechanical Engineering

Brakes are the most critical safety system on any performance vehicle, and as Cal Poly Racing transitions their Formula SAE car from a single rear motor to a four-in-wheel motor setup with regenerative braking, the team identified an opportunity to develop a bespoke brake caliper tailored to their specific needs. This document outlines the research, design, manufacturing, and validation of custom front brake calipers designed to improve upon commercial motorcycle calipers in key areas such as serviceability, mounting rigidity, thermal behavior, mass, and hub motor integration. The resulting design is a two-piece, four-piston, radially-mounted aluminum caliper featuring titanium pistons, toolless …

Cvj Torque Loss Dynamometer, Malaika Sriram, Coleman Brown, Zachary Norris, Logan Mast, Chris Mattis

Mechanical Engineering

This report details the design and results of a dynamometer testing rig built to measure torque losses in constant velocity joints (CVJs) for Cal Poly Racing's Baja SAE team. The rig spins a flywheel connected to articulable CVJs up to 800 RPM using a motor, then decouples it and measures the spin-down rate from 800 to 100 RPM to calculate angular acceleration and torque loss. The data collected from this dyno will be used to inform freewheel packaging for future Baja car development.

Design And Development Of A 12-Degree-Of-Freedom Quadruped Robot, Kai De La Cruz

Master's Theses

This thesis presents the design, analysis, and experimental validation of a 12-degree-of-freedom (DOF) quadruped robot developed as a research platform for legged locomotion and control. The system builds upon the Cal Poly Legged Robotics Group’s prior 8-DOF quadruped, addressing key limitations in manipulability, load distribution, and mechanical robustness by introducing a 3-DOF leg architecture.

The mechanical design emphasizes lightweight construction, structural integrity, and modularity to support future research extensions. Static and dynamic loading models were developed to inform component sizing and material selection. A carbon-fiber chassis and redesigned leg assemblies were fabricated and validated through finite element analysis and physical …

A Virtual-Reality-Based Dental Simulator For Endodontics With Automated Formative Feedback, Yousef Salah Abo El Ela

Theses and Dissertations

Advancements in virtual reality (VR) and haptic technology are transforming the landscape of medical and dental education, offering new avenues for safe, immersive, and repeatable training experiences. Within dentistry, endodontics presents unique challenges for preclinical education due to anatomical complexity, limited access to extracted teeth, ethical concerns, and the shortcomings of conventional plastic models. Despite endodontics specific plastic teeth being available, they fall short of replicating the hardness of real extracted teeth, are relatively costly compared to generic plastic teeth, and are ultimately a disposable item which makes them inadequate as a sustainable long-term solution. Extracted teeth do a much …

Teleoperated Robotic Arm With Vision-Based Imitation Learning, Favour E. Emmanuel, Hunter J. Donahue

Williams Honors College, Honors Research Projects

This report presents the design, development, and deployment of a teleoperated robotic arm system capable of vision-based imitation learning. The system uses a leader-follower architecture with myArm C650 and myArm M750 robots manufactured by Elephant Robotics. The leader arm movement is controlled by the operator, whereas the follower performs actions acquired from demonstrations. Data collection included synchronized joint-angle recording and multi- camera video streams capturing human demonstrations.

These demonstrations were processed with a deep learning imitation algorithm called Action Chunking with Transformers (ACT). The main capability of this algorithm is its ability to make future action predictions based solely on …

Areosense, Josephine Turney

Williams Honors College, Honors Research Projects

The AeroSense growing system is designed to make indoor aeroponic gardening easy and accessible for everyone. By combining sensors, automation, and AI, the system can monitor and adjust humidity, lighting, and nutrient levels to help plants thrive without requiring expert knowledge. The goal is to create a self-regulating garden that takes the guesswork out of growing fresh herbs and vegetables at home. The project involves building a working aeroponic prototype equipped with misters, pumps, and environmental sensors, all managed by a Raspberry Pi. Using computer vision and machine learning, AeroSense will be able to assess plant health and respond automatically …

Measuring The Impact Of 3d Printers On The Health Of Youth, Alexis Kostin, Olla Obeid, Oz Trost

Wetterhahn Science Symposium Posters

3D printers are used more widely than ever before; they can be found in factories, hospitals, and even schools. However, the health effects of the VOCs and UFPs that these machines emit have yet to be fully understood. In collaboration with the University of Nevada, Las Vegas, this study utilizes an Air Gradient One sensor at the Diamond Lab to monitor VOC and UFP emissions before, during, and after 3D printing sessions. By comparing these levels to EPA and CDC safety standards, we aim to quantify the respiratory risks posed to youth.

Influence Of Motion Artifacts On Instantaneous Frequency Based Heart Rate Variability Of Arterial Pulse Signals Measured By A Tactile Sensor: An Analytical Study, Mamun Hasan, Zhili Hao

Mechanical & Aerospace Engineering Faculty Publications

Objective: Heart rate variability (HRV), quantified via the instantaneous frequency (IF) of arterial pulse signals, is a key indicator of cardiovascular (CV) regulation. This study presents a theoretical and experimental investigation of how motion artifacts (MA) influence IF-and thus HRVmeasured with a tactile sensor, emphasizing underlying mechanisms rather than population-level validation. Approach: Building on a previously developed single-degree-of-freedom (SDOF) model of the tissue-contact-sensor (TCS) stack between the sensor and the artery, MA is represented as low-frequency baseline drift and time-varying system parameters (TVSP) of the TCS stack. Analytical expressions quantify the effect of MA on the IF of each harmonic …

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Parts, Logan Trimmer

Harrisburg University Other Works

Presentation covering the broad strokes of the project. The goal was to prove the viability of hybrid/additive manufacturing for high stress automotive applications. This project focused on recreating a piston from an old engine to examine if hybrid manufacturing could be used for such applications. On a small scale, hybrid manufacturing was able to be more cost effective if the costs of the equipment and electricity were ignored. The decision to ignore those costs came from the inability to find accurate prices for industrial casting.

Lift And Drag Benefits Of Morphing Aircraft, Joseph Lombardi

Master’s Theses

Aircraft use the ability to change the geometry of their wings to produce lift and drag as needed to maintain flight conditions. While the wings themselves are not physically changing shape, flaps and ailerons are used to alter the lift and drag coefficients experienced. Flaps have been used and changed over the years in order to produce better lift to drag ratios. The most commonly used flaps have been plain, slotted, and double slotted. Each type features slightly different mechanical structures, thus producing differing amounts of lift and drag. The introduction of new materials allow for a morphing flap to …

Ai-Based Porosity Detection In Babbitt Bore Turning, Kaylee Leggett, Hannah Adams Gemmell, Kaisa Shingleton

Williams Honors College, Honors Research Projects

For this project, an external company reached out to the University of Akron requesting assistance with defect detection during their vertical turning operations. As babbitt is removed in a vertical turning process, it occasionally reveals defects, mainly porosity, which can lead to costly downstream failures of the part. Current inspection techniques involve use of dye penetrant, which is time consuming, labor intensive, unergonomic, and a source of human error. The goal of the project is to create an alternative inspection method using an AI-based machine-learning model. After the turning operation, a camera is deployed to perform an in-place inspection, taking …

Optimized Returning Floating System (Orfs/Orfeus), Jordan A. Mcclelland, Adam J. Belluardo

Williams Honors College, Honors Research Projects

We are developing a proof-of-concept modified guitar tremolo system for an electric guitar that can automatically optimize tuning adjustments when a player transitions between tuning schemes using a cam system. Currently, changing tunings takes about 10–15 minutes because adjusting the tension on one string affects the tension of the others. Our design aims to compensate for these interactions and significantly reduce the time required to switch tunings.

Akron Soap Box Derby Super Kids Car, Alexis Schultz, Cooper Sites, Sean Stevenson

Williams Honors College, Honors Research Projects

This project aims to redesign the All-American Soap Box Derby Super Kids vehicle to enhance safety, accessibility, and performance while maintaining full compliance with official regulations. The Super Kids program enables children with physical and cognitive disabilities to race alongside a co-pilot, but the current vehicle design presents challenges in stability, entry/exit accessibility, and control—especially following recent regulation changes that increased vehicle speed. The redesigned car will focus on improved ergonomics, lightweight construction, and structural integrity within a $1,000 budget and a 165 lb weight limit.

An iterative engineering design process will guide the project through research, CAD modeling, FEA …

Automated Soil Resetting System For Extraterrestrial Regolith Simulation, Parker W. Brennan, Anthony C. Daniels

Williams Honors College, Honors Research Projects

This project focuses on designing an automated soil resetting system for extraterrestrial regolith simulation. The system will prepare a regolith simulant testbed to a desired, repeatable density, enabling reliable wheel–terrain testing for planetary rover research. Manual soil preparation currently exposes testers to hazardous particulates and produces inconsistent results.

The proposed system will integrate mechanical and control elements to reset the soil bed safely and efficiently. A combination of raking and vibrational methods will be explored, with feedback sensors and automation to achieve target density control. The research will proceed through literature review, benchtop experimentation, prototype design, and full-scale testing over …

Modeling And Testing Chain Trencher Excavator And Cone Penetrometer Robotic Prospecting Systems For Lunar In-Situ Resource Utilization, Marcello C. Guadagno

Dissertations, Master's Theses and Master's Reports

The Artemis Missions aim to establish a sustained human presence on the Moon, requiring In-Situ Resource Utilization (ISRU) of water-ice deposits in permanently shadowed regions. Two critical capabilities must be developed to enable ISRU at scale: prospecting instruments that can characterize the spatial distribution and geotechnical properties of icy regolith in situ, and excavation systems that can extract hardened icy regolith efficiently. This dissertation addresses both needs through the development and testing of a Percussive Heated Cone Penetrometer (PHCP) for geotechnical prospecting and a chain trencher excavator for icy regolith mining.

The PHCP was developed across eight design iterations and …

Investigation Of The Impact Of The Shape Of The Wings On Formula E Racing Car Performance: Enhancements For Optimal Aerodynamics, Ednie Marthe Adlaikah Jozil

Honors Undergraduate Theses

The aerodynamic performance of a Formula E chassis significantly dictates its overall race efficiency, directly impacting crucial parameters such as battery range and thermal management. This thesis investigates the external aerodynamics of the baseline Gen 2 Formula E car and evaluates the performance gains of two novel aerodynamic packages: a "Fully Modified" configuration and a "Flat Rear Wing" design. Computational Fluid Dynamics (CFD) simulations were conducted to analyze drag coefficients (Cd), downforce generation, and vehicle wake structures at race-relevant free-stream velocities (e.g., 37 m/s and 89 m/s). To ensure numerical robustness, the computational setup was validated using a smooth sphere …

Automation And Habitat Development For A Space Based Marine Life Environment, Logan Trimmer, Alexander Hang

Harrisburg University Other Works

This project was a cross-collaboration between the Environmental Sciences and Advanced Manufacturing and Robotics programs for the company Monolith Space.

The goal of this project was to design an autonomous system to be able to track qualities of water in an aquaculture system designed to be sent to space.

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Components, Logan Trimmer

Harrisburg University Other Works

The goal of this research was to establish the viability of using hybrid manufacturing for automotive applications. By verifying that high-stress components can be created, it can be assumed that any other lower stress part could be made to match the strength requirements. A limiting factor of adoption for hybrid manufacturing is how new the technology is. Studies on time and cost were performed allowing for comparisons with traditional manufacturing technologies (casting, forging, milling) used in automotive applications. This research utilized a Haas Automation UMC750 5-axis CNC mill with a Meltio laser wire direct energy deposition attachment. Fusion 360 was …

Development And Validation Of A Multi-Output Neural Network-Based Virtual Temperature Sensor For Electric Vehicle Thermal Management, Dalton Michael Wiggins

Graduate Theses, Dissertations, and Problem Reports (ETD)

Battery electric vehicles (BEVs) rely on accurate thermal management to ensure component performance, efficiency, safety, and long-term durability. Critical propulsion system components, including electric motors and high-voltage battery packs, are commonly monitored using physical temperature sensors. However, these sensors increase system cost, introduce additional hardware complexity, and may be impractical for directly measuring temperatures at critical internal locations. Virtual temperature sensors (VTSs) provide a software-based alternative by estimating component temperatures using readily available vehicle operating data.

This research presents the development and validation of a long short-term memory (LSTM) neural network-based virtual temperature sensor capable of simultaneously estimating the motor …

Aerodynamics And Heat Transfer In Polymer Blown Film Processing: Experimental And Numerical Investigation, Mohammad Luqman Zulbakri, Nur Atiqah Mat. Rautin, Raa Khimi Shuib, Ku Marsilla Ku Ishak, Auratus Zuratul Ain Abdul Hamid, Mohamad Danial Shafiq, Mohamad Yusof Idroas, Muhammad Khalil Abdullah

Makara Journal of Technology

The effects of airflow dynamics, heat transfer, and mechanical properties on the HDPE blown film extrusion process were examined using a single-lip air ring with a fixed compressed-air valve opening angle of 10°. Reynolds numbers ranging from 9175 to 25911 were analyzed to understand their impact on cooling efficiency, bubble morphology, and film properties. Numerical simulations employing the Standard k−ω turbulence model in ANSYS FLUENT v2023, with mesh refinement achieving y+ ≈ 1, captured detailed flow and heat transfer behavior. Results showed that higher Reynolds numbers significantly enhanced the heat transfer coefficient, with values increasing from 1096 W/m²·K at Reynold …