Manufacturing Commons^™

Surface Resistivity Correlation To Nano-Defects In Laser Powder Bed Fused Molybdenum (Mo)-Silicon Carbide (Sic) Alloys, Andrew Mason, Larry W. Burggraf, Ryan A. Kemnitz, Nate Ellsworth

Faculty Publications

The integration of Silicon Carbide (SiC) nanoparticles into Laser Powder Bed Fusion (LB-PBF) Molybdenum (Mo) printing represents a significant advancement in refractory metal additive manufacturing. Our investigation examined how varying SiC nanoparticle sizes affect the microstructural and electrical properties of LB-PBF-printed molybdenum components while maintaining a 0.01 mass fraction of Mo. At an Linear Energy Densities (LED) of 1.8 J/mm, the addition of 80 nm SiC particles achieved a 46% reduction in porosity, while sheet resistance decreased by 6% at LED of 2.0 J/mm with 80 nm SiC particles. These performance improvements stem from several mechanisms: SiC particles serve as …

Passive Vibration Isolation Systems For Mitigating Rotational Forces In Football Helmet Impacts, Julian Lee

LSU Master's Theses

Helmets have been used for centuries to mitigate head injuries, evolving with advancements in materials and design. They are critical in athletics, construction, and military applications, where shock and vibration isolation play a key role in head protection. Helmet performance is currently rated using the Head Injury Criterion (HIC) and Helmet Performance Score (HPS) metrics. HIC is a metric used in sports and automotive industries which focuses on the probability of injury occurring due to the magnitude and duration of linear acceleration of the head [1]. The HPS metric was created by using a linear combination of HIC and a …

Using Predictive Analytics To Reduce Small Business Cost Estimation Error, Diana Solt

Journal of Applied Packaging Research

Small and medium packaging companies generally employ the use of custom-developed quoting programs to bid goods and services. Custom bid programs (e.g. Excel) are used to capture the company-specific costs of production. The inputs of variable costs, such as machine rate and scrap rate, are critical to get correct; however, companies often rely on educated guesses and industry expertise to quote packaging products to end-users. Due to the guesswork involved there can be a financial difference between the quoted costs and actual costs. This variance is often the cause of significant lost dollars. Price, if not determined correctly, could negatively …

Experimental Characterisation Of Laser Cladding Of Crniw And Crnifealzr Powders On H13 Tool Steel And Optimisation Of Process Parameters, Martin Vinoth S

Theses and Dissertations

In this work, laser cladding on H13 steel substrate with two different powder compositions CrNiW and CrNiFeAlZr has been carried out. The laser power, powder feed rate, and scanning speed were varied and the clad dimensions, aspect ratio, and dilution percentage were measured. The microhardness found in the CrNiW clad is 834 ± 20 HV0.5, which is higher than that of the CrNiFeAlZr clad (780 ± 20 HV0.5) as well as the substrate (548 ± 20 HV0.5).

The X-ray Diffraction (XRD) patterns identified the common phase creation of Ni3C and Fe3C for CrNiFeAlZr and CrNiW coatings, while the oxide formation …

Mechanical Engineering Senior Design Capstone Modine Engineering: Collapsible Hvac Coil Expansion Table, Austin M. Hipskind

Honors Theses

For the Mechanical Engineering Senior Design class, teams of seniors were asked to find a sponsor company willing to provide a problem they were experiencing at a local plant. Using the skills gained throughout college, they were asked to go through a standardized problem-solving method to develop a solution for the sponsor company. I was teamed with Fernando Arellano and Henry Lindsey to work with Modine Engineering on creating a modular and collapsible table for use with large, custom-designed coils. This table would have to hold large, heavy coils during the expansion process. Modine requested a 3D design, the cost …

From Concept To Light: Manufacturing A Dual-Purpose Bedside Lamp And Book Organizer, Nicole Goulet

Honors Theses

This report features the design, development, engineering changes, and manufacturing of the Bedside Lamp, a hand-made multi-purpose lamp, book holder, and charging hub. The investigation began with research and a market analysis on current lamp designs and a discussion about what features would set the lamp apart. This led to the design of the lamp and construction of multiple prototypes for proof of concept.

A manufacturing process was then designed to demonstrate the steps to start up an efficient and cost-effective production line. This process included obtaining raw materials, cutting them into the necessary parts, and assembling everything to create …

A Product Development Process From Concept To Production: Smartphone Projector, Ross G. Cohen, Piper G. Thomas

Honors Theses

The purpose of this thesis is to demonstrate the production and documentation of the SmartPhone Projector Capstone for the Center of Manufacturing Excellence (CME). This document follows the production development from the beginning Spring 2024 problem definition all the way to the Fall of 2024 final product. This project was completed by a team of five undergraduate students, including an accounting major, finance major, biomedical engineering major, and two mechanical engineering majors. The goal of this project was to design and build a SmartPhone projector, then carry out a full production run located on the CME shop floor. To begin …

Exploring Manufacturing Techniques For Small-Scale Metal Fabrication And How They Can Be Optimized For Efficiency, Precision, And Scalability To Produce A Fire Pit, Henry W. Potter

Honors Theses

This thesis explores manufacturing techniques for small-scale metal fabrication, using a fire pit production as a case study to optimize efficiency, precision, and scalability. The study examines the challenges of small-scale manufacturing and analyzes alternative manufacturing techniques for cutting, joining, and surface finishing. Data was gathered through a case study involving the design and production of a fire pit. The manufacturing process included cutting, rolling, joining, and surface finishing. Alternative techniques, such as laser cutting and a paint sprayer, were compared to the methods used in the project. It was concluded that alternate methods offered improvements in efficiency, precision, and …

Thermal Characterization Of 3d Printing Materials For Increasing Insulation Potential And Practicality, Jackson H. Minnick

Mechanical Engineering Undergraduate Honors Theses

This study served as an exploration into the possible existence of a correlation between the infill lattice structure of a 3D printed wall section and the thermal performance of that sample as characterized by thermal conductivity measured in units of Watts per meter Kelvin. With the continual increase in the practicality, fidelity, and applicable fields of additive manufacturing, namely FDM 3D printing, research on specific print characteristics and their effects on the material and thermal characteristics of the part in question is steadily becoming more commonplace. Although the thermal conductivity of 3D printed wall sections as a function of infill …

Computational Modeling Of Torque Arm And Load Cell Interactions In Uta Racing Brake Dynamometer, Anthony A. Aiyedun

2025 Spring Honors Capstone Projects - Archive

The UTA Racing Team is developing a brake dynamometer to measure the coefficients of friction of various brake pads and calipers under controlled conditions. The dynamometer simulates on-track braking scenarios, testing brake pads at temperatures up to 1300ºF and pressures similar to racing environments. Its primary goal is to generate accurate friction vs. temperature graphs for various brake pad and rotor combinations, addressing the need for dedicated testing equipment. This project creates an ANSYS simulation of the torque arm and load cell interaction. The computational model accurately represents the relationship between applied torque and measured load cell force, incorporating precise …

Ultrafast Laser Surface Structuring For Wettability Control On Copper, Akshay Arvind Nagvenkar

All Theses

Wettability is a crucial surface property influencing various phenomena, including heat transfer, cell adhesion, and corrosion. Engineering devices can achieve superior performance by precisely manipulating surface wettability. As a result, extensive research has focused on developing surfaces that exhibit either extreme water attraction (superhydrophilic) or strong water repellency (superhydrophobic). Tailoring surface wettability paves the way for numerous applications, such as drag reduction in marine vessels, controlled drug delivery, efficient water collection, advanced liquid transport systems, oil-water separation, anti-corrosion coatings, friction reduction, and self-cleaning materials. Ultrafast laser surface structuring is a promising approach for engineering multifunctional surfaces, effectively modifying material properties …

Tradespace Exploration With Statistical Modeling Techniques And Immersive Visual Representation In Virtual Environments, Nikhil Raj

All Theses

Statistical modeling techniques combined with virtual reality (VR) visualization offer powerful new approaches to tradespace exploration in engineering design. The research presented addresses the challenge of analyzing and communicating insights from complex multidimensional datasets, particularly for autonomous ground vehicle systems.

Beginning with a review of statistical methods—including Principal Component Analysis (PCA), Analysis of Variance (ANOVA), and correlation analysis—the study examines their applications in tradespace exploration. Building on this foundation, three distinct visualization pathways connecting MATLAB data to virtual environments are developed and evaluated: VRML representation, STL conversion, and Blender integration. Each approach is assessed for its ability to maintain data …

Exploring Metal Additive Manufacturing In Martian Atmospheric Environments, Zane Mebruer

Mechanical Engineering Undergraduate Honors Theses

On-surface manufacturing is key to the success of a planetary colonization, especially that of Mars. However, traditional subtractive manufacturing processes are equipment, energy, and material intensive, meaning novel additive manufacturing (AM) processes must be pursued for this end. Selective laser melting, one of the most effective and versatile AM methods, would be incredibly beneficial to a Martian mission but requires an artificial argon atmosphere to create effective parts. The purpose of this study was to examine if carbon dioxide, the gas that makes up over 95% of Mars’ surface atmosphere, would be a sufficient substitute for argon in SLM fabrication. …

Adjustable Dynamometer Motor Mount, Garrett Carson Ng, Elijah Siegel Reuven, Ethan Fong, Daniel Larimer

Mechanical Engineering

The Cal Poly Electrical Engineering Department and sponsor Dr. Dolan needs a manufacturable motor fixture that securely aligns motors of various sizes with dynamometers. Previous lab motor fixtures could not accommodate motors of different sizes, making precise alignment between motors and dynamometers time-consuming and unreliable. Our team developed a modular, manufacturable fixture capable of aligning various motor sizes quickly, accurately, and securely, enhancing lab consistency and usability.

Baja Sae Brakes, Carson Moore, Jaedyn Michael Imhoff, Will Duncan, Matthew Shaffer

Mechanical Engineering

Historically, the Cal Poly Racing Baja SAE has produced a braking system that has proven unreliable and barely passes competition rules and inspections, leading to ill performing and unsafe brakes. The goal of this project is to produce a system and documentation that meets the requirements provided by Cal Poly Racing Baja SAE. The final design includes a transient braking model of the vehicle to set system requirements, universal custom front and rear calipers modified from “Cal Poly BSAE Custom Brake Caliper Senior Project”, and a revamped hydraulic harness. Leaning on the team’s previous work and modifying the custom calipers …

Carbon Fiber Cv Tripod Axle Design: Husker Motorsports Formula Sae, Taylor D. Boudreaux

Honors Program: Senior Projects (Public)

The 2024–2025 HMS Formula SAE senior design team successfully reduced axle system weight, cost, and improved manufacturability using a bonded tripod joint and ±45° intermediate modulus carbon fiber tube. The final design was validated on HMS 25, with no failures under rigorous testing.

Budget:
/="/"> Total project cost was $1,165.64, exceeding the initial $1,000 target due to unanticipated test rig expenses. However, per-axle production cost was reduced from $525.31 to $383.37 through in-house manufacturing, use of on-hand epoxy (DP460), and switching to cost-effective 7068 aluminum. The axle-specific cost was $766.74.

Timeline:
/="/"> Despite early delays from building a torsional testing …

Experimental And Theoretical Fracture Analysis Of Additively Manufactured Orthotropic V-Notches, Venkata Siva Sainath Bavapuram

Theses and Dissertations

This study presents a comprehensive investigation into the fracture behavior of additively manufactured orthotropic V-notched components made of Acrylonitrile Butadiene Styrene (ABS) material. The research integrates both theoretical and finite element approaches to evaluate stress intensity factors (SIFs) in Modes-I and II, which are fundamental in characterizing stress field distributions around notches under applied loading conditions. Unlike isotropic materials, where stress fields depend only on geometry of the component, the anisotropic nature of 3D-printed ABS introduces a dependency on material properties that necessitate different approaches to include anisotropy of the material.

Tensile specimens are 3D-printed with specific material orientations to …

Manipulating Martensitic Transformation And Residual Stress Development In Stress Superposed Incremental Forming Of Ss304, Elizabeth M. Mamros, Fabian Maaß, Thomas Gnaupel-Herold, A. Erman Tekkaya, Brad L. Kinsey, Jinjin Ha

Faculty Journal Articles

Stress superposition is one of the strategies used in metal deformation processes to increase the material formability, decrease the required forming forces, and create highly customized components. To investigate the effects of tensile and compressive stresses superposed to the single point incremental forming (SPIF) process, experiments and numerical simulations were conducted for a stainless steel 304 (SS304) truncated square pyramid geometry. Tensile stresses were superposed in-plane on the specimen blank by a custom hydraulic frame, and compressive stresses were incorporated via a polyurethane die. Identified parameters for a martensitic transformation kinetics model for SS304 were used in a two-step finite …

Advanced Porosity Control Of Cp780 Galvanized Steel During Gas Metal Arc Welding With Pulsed Arc, Carlos Adrián García Ochoa, Jorge Alejandro Verduzco Martínez, Francisco Fernando Curiel-López, Víctor Hugo López-Morelos, Jaime Taha-Tijerina, Ariosto Medina Flores, Maleni García Gómez

Informatics and Engineering Systems Faculty Publications

This study investigated the control of porosity during gas metal arc welding with pulsed arc (GMAW-P) of complex-phase 780 (CP780) galvanized steel. Due to the Zn coating on this type of steel, porosity forms during welding as a result of Zn vaporization. The objective was to optimize the welding parameters to minimize porosity with a design of experiments using an L9 orthogonal array to analyze the effects of peak current (Ip), pulse time (tp), and pulse frequency (f) in high-speed welding conditions. The results showed that porosity was significantly reduced with a peak current of 313 A, a frequency of …

The Prototype Of A Fully Automated Pressuremeter For Various Geotechnical Applications, Anuar Akchurin

Theses and Dissertations

The geotechnical engineering field requires high-quality in-situ testing equipment that ensures consistency in the test execution. This research focuses on developing and testing a prototype of a fully automated pressuremeter control unit to allow the industry to obtain reliable and controlled stress-strain data, thereby improving efficiency and reducing testing time.

The objectives of this work are to design and develop a system with the necessary components to perform the pressuremeter test, integrate the testing procedure into the state machine design, enable automated testing, and validate the results by comparing the stress-strain data with that obtained from the existing hand-operated pressuremeter …