Manufacturing Commons^™

Headlamp/Bike Light Damping System, Ethan Reece Clark, Alec Stonehouse, Omeed Ostry, Mitchel Anderson

Mechanical Engineering

The task for this project is to design a headlamp and/or bike light that absorbs the impact shocks from the user’s actions. The user that the system is being designed for may be riding a bike or running on a trail in the evening or early in the morning where the light needs to be stabilized and their path must be illuminated. This report presents the final design chosen after months of prototyping and design iteration. It encompasses the system design, design verification through testing, implementation, future recommendations, and lessons learned throughout the process. The chosen design utilizes a fully …

In-Situ Mechanical Tester, Andrrew Murach, Gustavo Marquez, Kosimo Tonn, Jake Vormbaum

Mechanical Engineering

Over the course of the 2022-23 Cal Poly SLO school year, a small tensile tester device was developed specifically for Dr. Long Wang to test thin film materials under a microscope and generate accurate force versus displacement graphs. A tensile tester was manufactured using purchased and machined components, electronics were consolidated in a separate box and connected, and a program and user interface were written to control the motion, provide custom inputs, and organize useful data for the researcher. Tests were conducted to compare the performance of the device to universal tensile testers available in the Composites lab. The device …

Disc Golf Throwing Robot, Nevada S. Schultz, Sydney M. Lewis, Erick Edmundo Daza, Rachel Alysse Greenberg, Peter M. Kean

Mechanical Engineering

Disc golf companies need better methods to test disc flight. The scope of this project is to create a disc throwing robot that can throw a disc golf driver 450-500 feet, with control over the speed, spin, and release angle. Research shows that multiple disc-throwing products exist; however, none meet the full requirements of this project. The Cal Poly senior project design team created a proof-of-concept machine. This prototype started as a two-wheel mechanism. Eventually, a third wheel was added, allowing for complete control over disc spin. The three-wheel prototype reached 62 mph when perfectly calibrated. The prototype is accurate, …

The Center For Centering Dome, Olek Piechaczek, Ryan M. Scharf

Architectural Engineering

The Center for Centering seeks to create a large-scale healing center, conducive to individual centering of the mind and body. This mobile installation provides a relaxing, enclosed space while still maintaining a connection to the outdoors. The clients liked the idea of having a pop-up installation that could be easily set up as a touring display. With a deadline for installation looming in June 2022, a team of students had five months to design and manufacture the structure.

In winter 2022, the students developed custom geometry to minimize the number of individual parts and built a ¼ scale model of …

Prove Primary Battery Structure, John D. Burkhart, Andy Mccormick, Ryan Yu, Soren Barclay

Mechanical Engineering

In conjunction with Prototype Vehicle (PROVE) Laboratory, our group designed, manufactured, and tested a prototype structure to house the battery boxes for PROVE’s endurance vehicle. Our structure was designed to support the batteries during normal use, and in the event of a front crash. Our design is comprised of a secondary composite box to house the battery boxes, a bottom plate to affix the secondary box to the chassis floor, a horizontal plate fastened to the chassis, and a brace structure welded to the chassis. From the outset, we chose to use a secondary box, the primary battery boxes must …

Parametric Bicycle Yoke, Colin Reay, Walter Minehart, Robby Harrigan, Jordan Olson

Mechanical Engineering

This report outlines the entire design, fabrication, and validation process of a parametric yoke design that addresses the packaging problem of the bottom-bracket chainstay junction in modern bicycle frames. The goal was to create an elegant, space-efficient solution that is accessible to the Cal Poly Bike Builders Club. The report includes documentation of the three-part fixture system, manufacturing process, and testing results for the yoke.

Our yoke design outperforms traditional round-tube weldments in torsional and vertical stiffness. Additionally, all manufacturing fixtures and machining operations function as intended, resulting in a finished yoke that meets all required tolerances in under an …

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 …

Programmable Vibration Table Retrofit With Eagle Medical, Jonathan Ilagan, Madhav Asok, Max Lewter

Biomedical Engineering

This project aimed to repair and upgrade a vibration table used for package testing for the sponsor, Eagle Medical - a medical packaging and sterilization company based in Paso Robles, California. The current vibration table is not programmable and lacks circuit diagrams, making it difficult to repair. In addition, it is not functional due to internal circuitry issues and power requirements. To address these issues, the team will implement several upgrades to improve the product and allow for better random cyclic vibration testing. A full assessment of the existing vibration table will be conducted to ensure the viability of these …

Thermal Transport And Physical Characteristics Of Silver-Reinforced Biodegradable Nanolubricant, Jaime Taha-Tijerina, Karla Aviña, Nicolás Antonio Ulloa-Castillo, Dulce Viridiana Melo-Maximo

Informatics and Engineering Systems Faculty Publications

In this investigation, the thermal transport behavior of biodegradable lubricant reinforced with silver nanostructures (AgNs) at various filler fractions of 0.01, 0.05, 0.10, and 0.20 weight percent was evaluated over a temperature scan analysis, ranging from room temperature up to 60 °C. The experimental results revealed significant gradual enhancements in thermal conductivity as AgNs concentration and evaluating temperatures were increased. These improvements showed the important role of nanostructures’ interaction within the biodegradable lubricant. The thermal conductivity performance improved for nanolubricants ranging from 6.5% at 30 °C and 0.20 wt.% AgNs content up to a maximum 32.2%, which was obtained at …

Experimental Investigation Of Various Energy-Absorbing Layer Materials And Sodium Alginate Viscosities On The Jet Formation In Laser-Induced-Forward-Transfer (Lift) Bioprinting, Shuqi Zhou, Chaoran Dou, Jianzhi Li, Qiqi Zhang, Qilin Dai, Ben Xu

Manufacturing & Industrial Engineering Faculty Publications

Laser-induced-forward-transfer (LIFT) bioprinting technology has been viewed as a regenerative medicine technology because of its high printing quality and good cell viability. To stabilize the jet to achieve high-quality printing, an energy-absorbing layer (EAL) can be introduced. In this study, three materials (graphene, gelatin, and gold) were utilized as the EAL. The effect of each EAL on the jet generation process was investigated. Besides, the effect of graphene EAL thickness was addressed for various experimental conditions. The jet generation process using sodium alginate solutions with different concentrations (1 and 2 wt. %) was also discussed to investigate the effect of …

A Literary Survey On The Challenges Of Adopting Lean In Aerospace Production And Aviation Maintenance, Seanan C. Lee

Journal of Aviation Technology and Engineering

Lean production began as a new method for creating value through the elimination of waste, continuous process improvement by workers, and fostering respect for people. Despite its success in other industries, the significantly lower production volume, the substantially higher complexity, and the service-oriented nature of aviation maintenance demand significant adaptation of Lean principles to be effective. The lack of a holistic study on Lean adoption for aerospace production and aviation maintenance organizations hinders transformation as the two industries are intertwined in product and characteristics. Lean adoption in aerospace production is hindered by the lingering notion that it is an ‘‘automotive …

Electromagnetically Actuated Modular Robots With Controlled Self-Assembly And On-Demand Disassembly, Anuruddha Bhattacharjee

Mechanical Engineering Research Theses and Dissertations

Modular reconfigurable robots, with on-demand assembly and disassembly, offer the possibility of mesoscale (milli- and microscale) manufacturing. However, most of the existing modular robotic platforms currently being designed and functionalized rely on complex actuation and assembly mechanisms and so lack further scalability and transformability required for mesoscale applications. Therefore, this dissertation seeks to develop a novel scalable modular robotic platform with controlled self-assembly, disassembly, and reconfiguration techniques using an external electromagnetic field. While current cutting-edge research in this area uses a single magnet to move one module at a time into the target position, this dissertation explores processes to move …

Crafting Comfort: The Design And Production Of A High-End Poolside Lounge Chair, John Hollis Tackett, Robert Griffis

Honors Theses

This report focuses on the development, design, and manufacturing of the Adjustable Lounge Chair, a high-end poolside lounge chair created to address un-met customer demand in the market. The investigation began with a market analysis to identify sought-after features not currently offered by competitors' products. This analysis drove the design of the chair, which was developed using CAD software, followed by the construction of a physical prototype to validate the concept.

The chair's innovative features include adjustable lumbar support and chair height, as well as a removable face-piece that enables users to comfortably lie prone without straining their necks. These …

The Engineering Challenges Of Designing And Manufacturing A Tensegrity Cup Stand, Yaniv Goulet, Daniel Ferro

Honors Theses

Progressing from a simple idea into a fully developed product is one of the main goals of any engineer. Through Haley Barbour Center for Manufacturing Excellence’s capstone program, the team was tasked with realizing a tensegrity cup stand. The tensegrity structure consists of a top and a bottom of some form only supporting itself by tension. The team had to research the concept, create an initial design, create a prototype of the product, improve the design after the prototype’s mistakes, apply lean principles to improve the manufacturing efficiency, and analyze all the economic impacts of the engineering decisions. In the …

Exploring Methods For Recycling Filament Waste In 3d Printing, Max Rios Carballo

Publications and Research

The goal of the current study is to investigate cutting-edge techniques for recycling filament waste from 3D printing procedures. Appropriate waste management techniques are required to reduce this trash's harmful environmental consequences. The goal of the project is to look at new methods for recycling filament waste in order to minimize disposal and encourage reuse. To acquire data from pertinent papers and research, a thorough literature review methodology was used. The findings show that this issue may be resolved utilizing a variety of recycling techniques, including shredding, melting, and re-extrusion. The type of filament waste and the intended goal will …

A Proof-Of-Concept Study For An Elastohydrodynamic Seal Design, Cameron M. Stuart

Honors College Theses

Supercritical CO₂ (sCO₂) power cycles are superior to traditional water based, air-breathing, direct-fired, open Brayton cycles or indirect-fired, closed Rankine cycles in terms of efficiency and equipment size. They hold great potential in fossil fuel power plants, nuclear power production, solar power, geothermal power, and ship propulsion. To unlock the potential of sCO₂ power cycles, utilized technology must withstand 10–600 MWe and at sCO₂ temperatures and pressures of 350–700℃ and 20–35 MPa for nuclear industries. Amongst many challenges at the component level, the lack of suitable shaft seals for sCO₂ operating conditions needs to …

Cycle Time Reduction In Additive Manufacturing Using Peltier Thermoelectric Cooling Devices, Trevor Carlton

Honors College Theses

Thermoelectric cooling and the Peltier effect were discovered in 1834, over 188 years ago. Additionally, the first iterations of additive manufacturing (i.e., 3D printing) began in the early 1980s, more than 40 years ago. Despite these technologies’ age and years of advancements, the application of Peltier cooling-based devices in additive manufacturing has not yet been realized. These devices can be used for the active thermal management of print beds in 3D printers. Developing a mechanism to heat and cool a print bed can reduce the cycle time to manufacture a part. In 3D printing, waiting for the heated bed to …

Developing Executable Digital Models With Model-Based Systems Engineering – An Unmanned Aerial Vehicle Surveillance Scenario Example, Viviana Guadalupe Lopez

Theses and Dissertations

There is an increase in complexity in modern systems that causes inconsistencies in the iterative exchange loops of the system design process and in turn, demands greater quality of system organization and optimization techniques. A recent transition from document-centric systems engineering to Model-Based Systems Engineering (MBSE) is being documented in literature from various industries to address these issues. This study aims to investigate how MBSE can be used as a starting point in developing digital twins (DT). Specifically, the adoption of MBSE for realizing DT has been investigated, resulting in various literature reviews that indicate the most prevalent methodologies and …

Engineering 3d Architected Metamaterials For Enhanced Mechanical Properties And Functionalities., Huan Jiang

Electronic Theses and Dissertations

Compared with conventional materials, architected metamaterials have shown unprecedented mechanical properties and functionalities applications. Featured with controlled introduction of porosity and different composition, architected metamaterials have demonstrated unprecedent properties not found in natural materials. Such design strategies enable researchers to tailor materials and structures with multifunctionalies and satisfy conflicting design requirements, such as high stiffness and toughness; high strength with vibration mitigation properties, etc. Furthermore, with the booming advancement of 3D printing technologies, architected materials with precisely defined complex topologies can be fabricated effortlessly, which in turn promotes the research significantly. The research objectives of this dissertation are to achieve …

Performance Of A Solar Seawater Distillation With A Triangle Prism Cover And A Fin-Type Absorber, Risse Entikaria Rachmanita, Miftah Khoirul Umam

Makara Journal of Technology

Solar-powered distillation is a seawater distillation method that utilizes solar heat as its main energy source for the purpose producing freshwater and a by-product of the distillation process in the form of salt. This study aims to determine the performance of a solar seawater distillation design with a semi-batch system by combining a fin-type absorber plate and a triangular prism cover. This design is equipped with a reflector and absorber plate, which has a surface area of 0.3969 m2 with a volume capacity of seawater that can be accommodated in a basin of ±24 liters. It uses a knockdown system …