Manufacturing Commons^™

The Deflection And Heat Transfer Analysis Of Injection Mold Cavity With Sla Cooling Channel Insert, Olumide Temidayo Aladesiun

Theses and Dissertations

Fast cooling in injection molding is the critical in the process economy. Among many different cooling channel designs available, conformal cooling offers the best and the most efficient cooling. However, limited awareness, accessibility, complexity, cost, knowledge, and experience limit the use of conformal cooling channels to be used into the mold in a molding process.

Typically, SLM(Selective Laser Melting) method is used to create cavity inserts with conformal cooling channels, however, due to the difficulties listed above, applications of conformal cooling channels are very limited. For an inexpensive alternative SLA (Stereolithography Apparatus) can print cavity inserts with conformal cooling channels. …

Novelty Ice Cream Assembly Prototype, Mason Sylvester, Logan Williamson, Alvaro Martinez, Adin Gilman-Cohen

Mechanical Engineering

Cool Beans USA is a novelty ice cream startup company founded by Keith Zachow. In the winter of 2022, our team began working with Mr. Zachow to develop a machine to automate parts of the production process for his product. This product consists of two hemispherical ice-cream cone shell halves filled with soft serve ice cream and pressed together. The assembled pods are around the size and shape of a small walnut and are intended to be sold in stores as a frozen finger food. At the time of project inception, this product was in its early stages and was …

Rotating Backing Brush, Caleb Savard, David Dalal, Max Allred, Mathis Weyrich

Mechanical Engineering

In the final steps of GAF’s shingle production process, small asphalt particles called fines are applied. Some fines adhere well to the shingle sheet, while others temporarily stick only to fall off the sheet further down the manufacturing line. As a result, the shingle plant floor is covered in fines that have fallen due to vibrations and gravity. The technicians and engineers at GAF want a cleaner working environment and to potentially reuse the loose fines. We are a senior project team that solved this problem by designing a system to remove and collect loose fines. In this document, the …

Baby Soothing Device, Grace Kalene Mekrut, Matteo Gozzini, Miles Angel Ibarra, Christian Joel Roberts

Mechanical Engineering

This document is the official final design review for the Baby Soothing Device. This product is intended to help families sleep throughout the night by allowing a baby to be soothed back to sleep without constant and direct parental interaction. It is maintained by Mechanical Engineering students at California Polytechnic State University, San Luis Obispo for Dustin Yoder, the project sponsor. The purpose of this document is to present the design process from ideation to finished design in great enough detail that its manufacturing procedure may be replicated if desired. This document further explains all the research, testing, and benchmarks …

Fabrication Of Solar Absorber Tube With Internal Fin Structure With In718 And Effect Of Boron With In718 For Solar Absorber Tube Using Selective Laser Melting 3d Printing Technology, Naznin Nuria Afrin

Theses and Dissertations

This research aimed to fabricate Solar Absorber Tubes for Solar-Thermal Power Plant with internal fin structures using Selective Laser Melting (SLM) technology. In this study, we investigated the effect of B with IN718 in 3D printing using SLM for solar absorber tubes. The objective was to study the material-process-properties relationship with goal to identify and validate the optimal parameters for the SLM process. Material selected for this study was IN718 with 0.5% and 1% B particle mixed using a V-shape mixing machine. The flowability test was conducted using the Angle of Repose (AOR) method. 3D printed samples …

A Numerical Simulation Of The Powder Bed Additive Manufacturing Process With Molecular Dynamics Simulation, Yeasir Mohammad Akib

Theses and Dissertations

Many manufacturing industries utilize powder bed fusion (PBF) since it can produce microscale precision 3D parts. During PBF, powder particles are selectively fused layer by layer using thermal energy. The build quality in the PBF process relies heavily on powder bed properties and thermal energy deposition. Powder flowability, spreadability, and packing fraction are some of the insightful factors that determine the quality of the powder bed. In this study, a two-dimensional powder bed is developed using the LAMMPS package. A cloud-based pouring of powders with varying volumes and initialization is adopted for the work. A blade-type and circular recoater is …

Ultrafast Laser Direct Writing Of Conductive Patterns On Modified Polyimide Film For Flexible Electronic Applications, Ishrat Jahan Biswas

Theses and Dissertations

Conductive patterns can be printed on a flexible polymer substrate using the direct laser writing (DLW) method. In order to write conductive circuits in such polymer using a laser, polyimide (PI) is a desirable material choice due to its electrical, chemical, and mechanical properties. Electrically non-conductive PI has shown great potential for flexible printed electronics as LDW enables selective carbonization in the bulk of such material leading to the formation of conductive lines. The technique is shown to be a rapid and minimal cost method for printing electrodes to nanoscale devices. However, investigations in this field show several limitations to …

A Study Of The Surface Properties Of Additive Manufactured Inconel 718 After Laser Surface Treatment And Cnc Grinding, Sampson K. Canacoo

Theses and Dissertations

This study investigated the surface properties of additive manufactured Inconel 718 produced through selective laser melting, and the effects of laser ablation and CNC grinding on the surface finish. The objectives were to investigate the effects of the various parameters of laser ablation and CNC grinding on the Inconel 718 surface. The parameters used for the laser experiments were pulse energy (4, 20, and 30 µJ), scanning speed (5, 10, and 15 mm/s), and hatch distance (10, 30, and 50 µm). For the grinding experiments, the wheel speed was kept constant at 20.3 m/sec, however, two different workpiece speed (8.6 …

Investigation Of Process Parameters To Fabricate Refractory Medium-Entropy Alloy By Selective Laser Melting Process, Abdullah Al Masum Jabir

Theses and Dissertations

This thesis proposal investigates the synthesis of TiWMo refractory medium entropy alloy (RMEA) by selective laser melting process from elemental powder. Steel, titanium and tungsten substrates were used to study the impact on the formation of TiWMo RMEA. Different process parameters were applied to investigate the effects on melting, diffusion and formation of RMEA. The microstructure of TiWMo and elemental distribution were observed by scanning electron microscope (SEM) and energy dispersive X-ray spectroscopy (EDS). SEM analysis revealed that with higher energy density the pores and microcracks were improved. EDS data validated the composition is homogenized and stable after few layers …

Femtosecond Pulse Filamentation In Dielectric Media Toward Photonics Sensor Fabrication, Anitha Narayanan

Theses and Dissertations

Through pulse filamentation, femtosecond laser pulses have been utilized to modify the refractive indices of dielectric materials such as glass, A-plane sapphire crystal, and Cplane sapphire crystal. The 10x Infinity Corrected Lens was used, and the focusing condition was tuned as being the same and fixed to both glass and sapphire crystals. First, 8uJ of laser energy was optimized to produce controlled pulse filamentation voids in the glass. The laser intensity was then optimized to 2-3.5 uJ, 1.5 uJ, & 2.5 uJ, respectively, for the controlled pulse filamentation in A and C plane sapphire crystals. Due to the different crystal …

Feasibility Analysis Of Embedding Optical Fiber Sensor Into Additively Manufactured Part, Mahmudul Hasan Porag

Theses and Dissertations

The research tried to examine the viability of the embedment of optical fiber sensors in Additively built components, packaging the sensors within the components, and characterizing the sensors for sensing a specified measurement. Optical fiber sensors are popular due to their small size, resilience against electromagnetic radiation, and reliability in potentially dangerous conditions. Embedding fibers inside a product allows for the monitoring of critical areas, allowing for preemptive action in the case of a breakdown. Coupons of Inconel 718 were made using laser powder-bed fusion (LPBF), with the fabrication settings tuned to determine whether such a development was possible. After …

Performance Comparison Of Several Control Algorithms For Tracking Control Of Pantograph Mechanism, Laylaa Mahmoud Eng, Mohamed Shamseldin Dr, Mohamed Sallam Dr, Abdelghany Mohamed Prof

Future Engineering Journal

A sort of parallel manipulator known as a pantograph robot mechanism was created primarily for industrial requests that required high precision and satisfied speed. While tracking a chosen trajectory profile requires a powerful controller. Because it has four active robot links and one robot passive link in place of just two links like the open chain does, it can carry more loads than the open chain robot mechanism while maintaining accuracy and stability. The calculated model for a closed chain pantograph robot mechanism presented in this paper takes into account the boundary conditions. For the purpose of simulating the dynamics …

Characterization Of Materials Properties In Additively Manufactured Aisi-420 Martensitic Steel Deposited By Laser Engineered Net Shaping, Md Mehadi Hassan

Nanoscience and Microsystems ETDs

Metal additive manufacturing (AM) is a disruptive technology enabling the fabrication of complex and near-net-shaped parts by adding material layer-wise. It offers reduced lead production time. AM processes are finding applications in many industrial sectors such as aerospace, automotive, biomedical, and mold tooling. Despite the tremendous advantages of AM, some challenges still prevent this technology's adoption in high-standard applications. Anisotropy and inhomogeneity in the mechanical properties of the as-built parts and the existence of pores and lack-of-fusion defects are considered the main issues in directed energy deposition (L-DED) parts. Laser-engineered net shaping LENS® offers excellent possibilities to fabricate metal tools …

Biomass Characterization And Insulation Optimization Studies, Hussein Awad Kurdi Saad

Doctoral Dissertations and Master's Theses

This study indicates how biomass materials can be effectively used as naturally sustainable alternatives to insulation materials. Barley grains and oak leaves, straw, and jute are collected, and crushed into powders/ chopped pieces. The physical characteristics are measured to characterize each powder. The biomass powder reinforced composites are manufactured in varying weight ratios. The density and thermal conductivity of composite materials are measured. The properties of composites compared to those of commercial insulation materials are found to be close to them. Furthermore, genetic algorithms (GA) can be used to achieve multi-objective optimization entailing maximizing insulation (minimizing heat transfer) and simultaneously …

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 …

Hypoxic Incubation Chamber, Simone Lisette Helfrich, Makenzie Nicole Jones

Biomedical Engineering: Graduate Reports and Projects

This paper describes the design, manufacturing, and testing of a novel controllable hypoxic incubator with fully functional oxygen gas control and temperature control in a humid environment. On the current market, a majority of the few hypoxic incubators use pre-mixed gas that does not offer precise control over gas concentration. The objective for this project was to create a chamber that allows the user to set the O2 concentration to varying set points of % O2 while maintaining the chamber at a constant body temperature, CO2 level, humidity, and sterility. To start the project, multiple concepts were developed for the …

Hypoxic Incubation Chamber, Simone Lisette Helfrich, Makenzie Nicole Jones

Master's Theses

This paper describes the design, manufacturing, and testing of a novel controllable hypoxic incubator with fully functional oxygen gas control and temperature control in a humid environment. On the current market, a majority of the few hypoxic incubators use pre-mixed gas that does not offer precise control over gas concentration. The objective for this project was to create a chamber that allows the user to set the O2 concentration to varying set points of % O2 while maintaining the chamber at a constant body temperature, CO2 level, humidity, and sterility. To start the project, multiple concepts were developed for the …

A Benchtop Robotic Automation Approach For Manufacturing Prefilled Syringes, Yehua Zhong

All Theses

Automation and robotics have become a staple in the biological manufacturing sector due to their ability to efficiently work without operator inputs, with a high degree of accuracy and repeatability. Industrial robotic arms, in particular, present themselves as valuable tools for biological manufacturing scenarios that require customized solutions due to their ease of programming and flexibility. The traditional hospital-focused healthcare system was organically developed to address acute conditions, however, in recent years, due to the unprecedented occurrence of emergencies happening more frequently, fast and efficient drug production becomes important [17]. This thesis represents the use of a benchtop robot and …

A Survey Of Smart Manufacturing For High-Mix Low-Volume Production In Defense And Aerospace Industries, Tanjida Tahmina, Mauro Garcia, Zhaohui Geng, Bopaya Bidanda

Manufacturing & Industrial Engineering Faculty Publications

Defense and aerospace industries usually possess unique high-mix low-volume production characteristics. This uniqueness generally calls for prohibitive production costs and long production lead-time. One of the major trends in advanced, smart manufacturing is to be more responsive and better readiness while ensuring the same or higher production quality and lower cost. This study reviews the state-of-the-art manufacturing technologies to solve these issues and previews two levels of flexibility, i.e., system and process, that could potentially reduce the costs while increasing the production volume in such a scenario. The main contribution of the work includes an assessment of the current solutions …

Reliability Study Of A New Electromechanical Device Designed To Measure The Relative Dorsal Mobility Of The First Ray Of The Foot, Philippe Passeraub

Faculty Publications

Introduction: A new electromechanical instrument has been developed to measure relative dorsal mobility of the first ray in an objective and reliable way by simulating ground reaction forces during gait. This device equally applies a standardized, electronically controlled, and precise force under the first metatarsal head M1 as well as under the heads of the lesser metatarsals M2 to M5. The relative dorsal mobility between these two bearings is then measured. The purpose of this study is to assess the intra- and inter-examiners reliabilities of the measurements obtained with this device. Methods: The protocol included two examiners and 36 feet …