Manufacturing Commons^™

Innovation-Driven Development Of Advanced Manufacturing Industry Clusters: Trends, Issues, And Implications For 15th Five-Year Plan, Mu Rongping, Jingjing Guo, Yuchen Li, Qiang Li, Ze Feng, Mengyuan Zhu

Bulletin of Chinese Academy of Sciences (Chinese Version)

Advanced manufacturing industry clusters have emerged as a key driver of global manufacturing transformation and upgrading, playing an increasingly significant role in technological innovation, industrial collaboration, supply chain resilience, and green, low-carbon development. This study systematically analyzes the innovation development trends of advanced manufacturing clusters worldwide, outlining the strategic layouts, policy measures, and implementation pathways adopted by major countries. Based on a comprehensive review of China’s current development status and prominent challenges in this field, the study proposes targeted policy orientations and recommendations. These policy recommendations include strengthening the innovation capacity of clusters, improving collaborative innovation networks, promoting the integration …

Structural Design And Finite Element Analysis Of A 54 Ton Freight Wagon Bolster Test Rig Under Vertical Center Plate Load, Shandy Dwi Prayoga, I Dewa Gede Ary Subagia, I Ketut Adi Atmika, Abdul Rohman Farid, Yunior Lanang Satrio

Journal of Mechanical Engineering Science and Technology (JMEST)

Bolster is one of the bogie's components that receives direct loading from the car body and freight movement. One of the problems that occurs in the bolster is permanent deflection during vertical and transversal static loading. Therefore, a static loading test is required to evaluate the structural strength of the bolster. During the static loading test, a rig is required to hold the bolster so that the bolster is in a fixed position. The rig owned by PT. INKA (Persero) showed a plastic deformation at the vertical center plate load (VCP 5.22P). Therefore, a modified design of the rig is …

3d Semi-Analytical Thermo-Elasto-Plastic Model For Additive Manufacturing, Tao Liu, Ming C. Leu, Edward C. Kinzel, Chinedum Okwudire

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In additive manufacturing (AM), stress field drives distortion and warping and promotes delamination and cracking. Fast, accurate stress prediction is therefore essential for AM process planning and control, including real-time adaptive control, AM digital twins, data-driven and physics-driven workflows. However, spot-wise thermo-elasto-plastic finite element method (FEM) are often too slow for design iteration or real time use. Existing semi-analytical thermo-elasto-plastic approaches achieve high speed but are largely limited to 2D. In this paper, a full 3D semi-analytical thermo-elasto-plastic model for AM is built. The method uses a spot-wise analytical thermal field as the load and computes displacements and stresses via …

Optimization Of Aluminum Coating Deposition Parameters To Enhance The Performance Of Automotive Headlamps, Gulirano Saidakhmedova, Giovanni Maizza

Technical science and innovation

The paper investigates the influence of the optical characteristics of functional coatings applied to automotive reflectors on vehicle active safety parameters, with a focus on the range and intensity of road illumination. The study examines the mathematical relationship between the maximum luminous intensity of a headlamp, the object detection distance, and the reflection coefficient  of an aluminium layer deposited via vacuum thermal evaporation. The main factors driving the degradation of surface reflectivity (including oxidation, thermal degradation of the base coat, and surface roughness) are analysed. It is demonstrated that a decrease in the reflection coefficient during operation directly impairs the …

Magnetic Field-Induced Transformation In Polycrystalline Ni2mnal Heusler Type Magnetic Shape Memory Alloy, Choji J. Daches, Joseph W. Newkirk, Mario Buchely, Laura N. Bartlett

Materials Science and Engineering Faculty Research & Creative Works

The martensitic and magnetic transformations, as well as the mechanical properties, of Ni₂MnAl alloys in as-cast (AC) and heat-treated (HT) conditions were investigated. Magnetic-field-induced strain was evaluated via magnetostriction, with reversible strains of 0.14% and 0.2% achieved in the martensitic phase at 2 K for the AC and HT alloys, respectively. Transformation temperatures and Curie temperatures were determined under constant applied magnetic field, revealing that γ-phase inclusions in the AC microstructure suppress antiferromagnetic domain response, yielding a lower magnetization (∼8.4 emu g⁻¹) compared to the HT alloy (∼13.4 emu g⁻¹). Both alloys exhibited hysteretic behavior in the martensitic state and …

Direct Ink Writing Of Functional Fiber/Granular Composites, Zhuoyuan Yang

Doctoral Dissertations and Master's Theses

Direct ink writing provides a versatile manufacturing route for fabricating functional fiber and granular composites with controlled architecture, tunable interfaces, and customized material distributions. Fiber reinforced composites offer high stiffness, strength, fatigue resistance, and functional anisotropy, while granular composites provide scalable access to particle based structures with high material efficiency and broad resource compatibility. However, the additive manufacturing of these composite systems remains challenging. For fiber based composites, precise control of fiber placement, matrix impregnation, interfacial bonding, and freestanding deposition is difficult to achieve during printing. For granular composites, stable particle flow, controllable packing, binder infiltration, and shape retention are …

Multidisciplinary Inverse Robust Co-Design Of Materials, Products, And Manufacturing Processes, H M Dilshad Alam Digonta

Theses and Dissertations

Realizing the design for Integrated Computational Materials Engineering (ICME) requires the materials, product, and manufacturing-process disciplines to be designed together. Because these disciplines interact and influence one another's decisions, coordination is needed among their distributed decision-makers. Their interactions are captured through the processing-structure-property-performance (PSPP) linkages, which must be established from limited, costly data. Moreover, each discipline introduces its own sources of uncertainty, and these propagate through the process chain to influence final product performance. The effective realization of the product-material-manufacturing system, therefore, calls for a co-design approach that enables the concurrent coordination of the interacting disciplines while quantifying and managing …

Production Of Seismic-Resistant Steel From Scrap With Up To 0.6% Copper, Iman El-Mahallawi, Ahmed Ramadan Seada Dr.

Mechanical Engineering

Earthquake-resistant steel grades of characteristic value defined by the ratio (UTS/YS) greater than 1.25 are verified through controlling the proportion of alloying elements in steel. This work illustrates a novel idea to produce earthquake-resistant steel grade utilizing steel scrap. Different heats were produced containing varying levels of copper, manganese, and silicon, along with deep desulfurization. The heats were hot rolled to diameters of 10, and 16 mm, followed by Tempcore process. JMatPro software was used to predict the formed phases. The chemical composition was determined by optical emission spectrometry. The tensile properties were determined by tensile testing, and bend testing …

Trajectory-Based Model Predictive Control For Rotary Crane Sway Suppression With Only Horizontal Boom Actuation, Haryson J. Nyobuya

Tanzania Journal of Engineering and Technology (TJET)

Safety is of biggest importance in construction and industrial activities involving rotary cranes. These cranes are huge and responsible of moving large parts or/and materials from different positions. Now operating these cranes tend to be subdue to pay load oscillations when moving the load for which is extremely dangerous when not suppressed. This study proposes the generation of trajectory using Model predictive control approach with reduced control horizon compared to state horizon. Reduced control horizon design reduces computational time for trajectory generation while maintaining the pay-load sways to a minimum. In this approach the complex dynamic model is reduced to …

Enhancing The Barrier And Mechanical Properties Of Kraft Paper For Food Packaging Using Poly (Lactic Acid) Coatings Via Dip-Coating Technique, Putu Hadi Setyarini

Makara Journal of Science

Moisture-resistant kraft paper is important for food packaging because it helps preserve product quality and extend shelf life. However, untreated kraft paper exhibits limited barrier performance owing to the porous and hydrophilic nature of its cellulose structure. Herein, the mechanical and barrier properties of kraft paper were enhanced by applying poly (lactic acid) (PLA) coatings using a dip-coating technique with PLA concentrations ranging from 1 to 5 g/100 mL and either single- or double-dip-coating cycles. The results showed that increasing the PLA concentration and applying a double dip-coating treatment consistently improved coating thickness, tensile strength, elongation at break, water resistance, …

Vibration Diagnostics For Industrial Machinery: From Signal Processing To Deep Learning, Walid M. Shewakh

Emirates Journal for Engineering Research

When machines break down unexpectedly, it costs factories a lot of money and can even put workers at risk. That is why vibration analysis has become such a big deal in predictive maintenance. By listening to how a machine vibrates, engineers can often tell something is wrong before the whole thing falls apart. This paper looks at how we have gotten better at this over the years. We started with fairly basic signal processing, things like Fourier transforms that have been around for ages, and now we are seeing some really interesting work with neural networks and deep learning. I …

The Effect Of Mwcnt-Oil Impregnation Of Sintered Components On Their Wear And Corrosion Resistance, Maha Khaled Abdelfadeel

Theses and Dissertations

Powder Metallurgy (PM) offers an advantageous route for manufacturing complex and near net-shape components. Their inherent interconnected porosity that promotes the action of self lubrication compromises their structural integrity by creating pathways for corrosion and excessive wear. This research investigates the efficacy of Multi-Walled Carbon Nanotubes (MWCNTs) as a nano additive within the impregnating base oil (SN-150 base oil). An experimental matrix was designed to evaluate the influence of MWCNTs with different concentrations of 0.05, 0.1, and 0.2 wt.% and ultrasonic dispersion with varying sonication times of 30 and 60 minutes on the tribological and electrochemical performance of sintered steel …

Rapid-Prototyping Nanofabrication: Lcd-Based Projection Lithography And Physical Vapor Deposition, Sabeel Saleem Mohammmed

University Honors Theses

The semiconductor industry's continued growth, driven in large part by demand for artificial intelligence hardware, has highlighted the need for greater workforce development in regions adjacent to major fabrication centers like Oregon's Silicon Forest. This capstone project lays the groundwork for a small scale and student led semiconductor fabrication lab at Portland State University by demonstrating two of the core steps in chip manufacturing: photolithography and thin film deposition. Rather than relying on conventional fixed reticles, this work explores a unique, low cost approach to patterning that uses an ultraviolet-compatible liquid crystal display (LCD) as a programmable reticle, allowing arbitrary …

Mars Rover Wheels And Drive, Presley S. Sacavitch, Ryan W. Trevena, Dylan A. Mack, Daniel Hudak

Mechanical Engineering

Cal Poly’s Poly1Rover team, advised by Professor Rich Murray, aims to deploy four student-designed mini-Mars rovers, each equipped with a sample-tube retrieval claw, before 2030. However, the wheels of Poly1Rover’s current 6th generation rover are not ready for deployment to Mars, as they do not utilize space-grade materials, are not optimized for manufacturability, and lack sufficient spoke compliance to absorb landing and high-impact loads. This project will be developed by a team of Mechanical Engineering students at California Polytechnic State University, San Luis Obispo (Cal Poly): Daniel Hudak, Dylan Mack, Presley Sacavitch, and Ryan Trevena. Next Intent is providing funding …

Formula Sae Planetary Gearbox Characterization Dynamometer, Trevor Marco Toma, Thomas Welden Pierce, Ethan Liu

Mechanical Engineering

This report outlines a custom hub motor dynamometer requested by the Cal Poly Racing FSAE team. The need for this testing platform is to characterize an existing Formula SAE planetary gearbox for a proposed 4WD powertrain. Hub motors, compact electric machines integrated directly into each outboard wheel, offer significant advantages in efficiency, traction, and chassis packaging compared to conventional RWD drivetrains. By mapping torque capacity, efficiency, lubrication method effectiveness, and fatigue life, the team can validate gearbox design and performance.

This senior project group designed and built a dynamometer according to these specifications which will allow for successful testing to …

Improving The Reliability And Performance Of A Supersonic Indraft Tube Wind Tunnel, Christian J. Kaml

Master's Theses

Access to supersonic testing is increasing in demand, and wind tunnels remain one of the safest and most cost-effective methods for gathering high-speed flow data. Despite being more economical than alternative options, supersonic wind tunnel facilities often require substantial investment to construct, operate, and maintain.

The novel indraft tube tunnel architecture was conceived as a high-speed flow testbed that incorporates features of both Ludwieg tubes and indraft wind tunnels to maintain costs low enough to be accessible even to small universities. This design was first developed and tested in 2018 at California Polytechnic State University, featuring a cost per test …

A Novel Hexagonal-Zigzag Cellular Infill Structure For Additive Manufacturing, Md. Saidur R Roney, Amm Nazmul Ahsan, Prosenjit Barua

Manufacturing & Industrial Engineering Faculty Publications

The rigidity of the Additively Manufactured objects can be tailored by manipulating the infill lattice type and density. In this research, an island type novel infill structure termed as Hexagonal-Zigzag pattern is introduced, and its mechanical performance is investigated. In this pattern, the zigzag raster reflects the repeating hexagonal shaped cell constituting the parallel-oriented islands and 90° rotation of the pattern in each layer distributes the island span along both transverse and longitudinal directions of the printing contour. A mathematical model is established to illustrate the effect of the infill parameters on hexagon unit cell size and relative infill density. …

Me3329 Modular Phonograph Gearbox, Garrett Andrik Leighton, Preston Robert Hupe, Gavin Carter Ebner, Andrew Renato Reyes

Mechanical Engineering

The Mechanical Engineering Department at California Polytechnic State University, San Luis Obispo (Cal Poly), seeks to develop a laboratory tool allowing students to reinforce concepts of gears for Mechanical Systems Design (ME329). Some current laboratories do not provide students with hands-on interaction, and the department lacks equipment and documentation to support a standardized lab. With ME329 expanding from ten to fifteen weeks, there is an opportunity to create a physical gearbox design lab allowing students to reinforce lecture material in engaging ways, while standardizing student learning. This senior project is presented and sponsored by Professor Alan Zhang. It will be …

Smart Sleeve, Evan Abalos, Bright Jung, Owen Bowling, Wyatt Eberhart

Mechanical Engineering

Quantifying human arm muscle activity is essential for understanding human movements and helping individuals who suffer from motor or neurological impairments such as stroke or traumatic brain injuries. Today, these individuals, as well as clinicians, researchers, and athletes, face many challenges when using the traditional surface electromyography (sEMG) systems to monitor muscle activities, including complex setup, restricted mobility, discomfort, inconsistent placement of electrodes, and lack of accuracy. Therefore, a comfortable EMG sleeve device that accurately measures arm movement without interfering with daily tasks is needed, which the team will be designing, manufacturing, and testing as their senior project. In addition, …

Process Improvement For Thermal Barrier Coating Masking Applications, Katherine Meezan, Aiden Senn, Saksham Giri, Katelyn Perez

Mechanical Engineering

Solar Turbines, a gas turbine manufacturer, needs a more efficient method to prevent the application of a thermal barrier coating (TBC) to select areas of their combustion liners during manufacturing. Currently, the process is labor, material, and time intensive: reusable masking tools should increase the efficiency of the TBC process.

This project is sponsored in full by Solar Turbines, and is under the guidance and administration of three Solar Turbines engineers: Chris Noone, Rick Rogers, and Carson Roff. The project is mentored by Cal Poly senior design Coach, Rick Lasko. This project will be completed by a team of four …