Manufacturing Commons^™

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 …

Mars Mini Rover Sample Retrieval Robotic Claw, Cami Chambers, Ani Lachikian, Alexa Ramirez, Alex Power

Mechanical Engineering

This project involves several key stakeholders, including the Poly1 Rover Club, Professor Rich Murray, and NASA’s Jet Propulsion Laboratory (JPL). The primary objective is to develop an improved robotic claw capable of retrieving sample tubes left by the Perseverance Rover on the Martian surface. In tackling this challenge, the design must account for the harsh Mars climate while integrating cameras and electrical components, durable structure, and a rotational component to the Mini-Rover claw without incorporating an additional motor, sample storage unit, structural aspects or unnecessary weight. The current Mini-Rover consists of a four-degree-of-freedom robotic arm with joints often referred to …

Sensory, Light, And Sound Box, Galilea Andrea Portillo, Hannah Elizabeth Henderson, Marcus Kiyoshi Kanenaga

Mechanical Engineering

The Sensory, Light, and Sound Box senior project outlined an adaptable, mobile sensory environment designed to improve cognitive and visual processing skills for students with Cerebral Visual Impairment (CVI) at the Oceano Education Center. Currently, the market lacks accessible solutions tailored to these non-verbal, low-mobility students, making traditional classrooms overwhelming. This project outlines the modification of an existing static layout into a functional, three-sided wooden over-bed frame that accommodates a standard hospital bed. Our team manufactured a structurally stable verification prototype under a $500 budget, integrating slow-closing outward-hinged walls for safety, dual Bluetooth speakers, and a synchronized LED projector that …

Stakblocks, Micah Satoshi Inoshita, Ava Rose Doerschlag, Cody J. Ellis, Zach M. Lawton, Fernando M. Nalin, Nicholas Humphrey, Aiden Reed Anderson, Sara Maya Suratkal

Mechanical Engineering

Researchers developing sustainable building materials from agricultural waste need a faster way to prototype and evaluate small-scale samples under controlled temperature and pressure before scaling to production. Sponsored by Professor Pete Schwartz of Cal Poly San Luis Obispo, whose work focuses on sustainable technology for developing communities, this project aims to create a prototype testing device for researchers studying agricultural-waste bricks, with the University of Malawi as a potential future testing partner. The final product is intended to inform improved future designs rather than serve as a production-ready device, ultimately supporting the development of affordable, sustainable building materials for communities …

Foldable Transfer Platform, Toby Sagi, Ashton Heiati, Triton Johnson, Zachary Denis

Mechanical Engineering

The report details the design and results of a Hoyer lift to transfer patients between wheelchairs and our sponsor's, Beacon VTC Santa Maria, vans. The lift disassembles into 3 main pieces, allowing the lift to be stored in the back of the van. The lift uses a hydraulic actuator to rotate the boom. We handed over our project to Beacon VTC Santa Maria for use in their facility!

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 …

Simulation Of Powder Spreading For Metal Additive Manufacturing, Florence Duff

Master's Theses

The powder recoating process for Laser Powder Bed Fusion requires iterative experimentation to develop the correct process parameters that will result in high quality parts. There currently lacks good spread quality metrics and models for optimizing spread quality. A machine that simulates the powder spreading process was built to streamline the process of selecting process parameters for specific types of powders without having to operate the full laser system. The parameters investigated were the layer thickness and spreading speed. The response variables were metrics developed to assess spread quality: the percentage of the build plate covered by powder and the …

Cal Poly Fluid Powered Vehicle Challenge 2025/2026, Ethan Malachi Nejame Zeiset, Christian Anthony Cuamani, Daniel Chacon-Bizarro, Marcus Minera, Bradley Hansell

Mechanical Engineering

In this Final Design Report, the Cal Poly Fluid Power Vehicle Challenge Contending Team competed in Sun Hydraulics’ 2026 Fluid Powered Vehicle Challenge. The objective of the competition is to expose college students to the fluid power sector, the “hidden giant” of the engineering industry. Specifically, student teams are tasked with the development of a human-powered, fluid-driven vehicle for use in various competitive settings. The team prioritized the optimization of an existing prototype for simplicity, ease of maintenance, and reliability during the competition. The existing prototype exhibited issues related to the main frame’s deflection under load, a lack of gear …

Investigation Of Process Parameters To Fabricate Tiwmo Refractory Medium Entropy Alloy Via Laser Powder Bed Fusion, Abdullah Al Masum Jabir, Lindsey A. Salazar, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications

This paper presents an experimental study on the fabrication of a TiWMo refractory medium-entropy alloy (RMEA) using laser powder bed fusion (PBF-LB/M, commonly known as selective laser melting) from elemental powders as well as successful alloy formation on titanium substrates. The effects of tungsten particle size and process parameters on successful TiWMo RMEA fabrication have been explored using scanning electron microscopy (SEM), x-ray diffraction, hardness measurement and microstructural analysis. Scanning electron microscope (SEM) analysis revealed that the lowest percentage (0.01%) of unmelted tungsten particles was observed at a laser power of 350 W and scanning speed of 250 mm/s, particularly …

Data Driven Estimation Of Pore Size Using 1d Light Emissions For Laser Powder Bed Fusion Additive Manufacturing, Jose Galarza, Jorge Barron, Luis Jimenez, Tamer Oraby, Jianzhi Li, Farid Ahmed

Manufacturing & Industrial Engineering Faculty Publications

The quality assurance of the Laser Powder Bed Fusion Process (LPBF) has been extensively investigated over the last decade for in-situ monitoring of metal additive manufacturing. The process inherently generates voids within the bulk of the part, which can detrimentally affect the quality of the printed part. The characterization of these voids by estimating their size and identifying their geometrical features remains a challenge. This study introduces a Machine Learning (ML) based framework for estimating void sizes of varying geometries using layer-wise one-dimensional (1D) average light intensity signal obtained from the optical tomography system during the 3D printing of metallic …

On The Application Of Machine Learning Techniques For Quality Assurance In An Automobile Paint Shop, Anis Fatima, Shakeel Ahmed, Muhammad Akif Shan

Michigan Tech Publications

The automotive industry depends on high-quality paint coatings for both aesthetic appeal and functional performance. However, surface imperfections such as scratches, paint runs, and orange peel can arise from process and environmental variations. This study employs machine learning (ML) and exploratory data analysis (EDA) to identify key factors that influence surface defect formation in automotive painting. Using historical production data from Lucky Motor Corporation Limited, models based on linear regression, support vector machines (SVM), and random forests were developed and validated under various process conditions. The best-performing model achieved an R² of 0.94, with a mean absolute error (MAE) of …

Effects Of Niobium On The Mechanical And Oxidation Properties Of Additively Manufactured Tungsten, Alexander Lesieur, Cayla Eckley, Ryan A. Kemnitz

Faculty Publications

Although additive manufacturing presents a novel and customizable approach to fabricating tungsten (W) alloys, the layer-by-layer production technique presents a unique set of processing challenges which are further exacerbated by the metal’s refractory properties. In this study, additions of niobium (Nb) were found to improve the mechanical properties and oxidation resistance of additively manufactured W. Microstructural investigation revealed the effect of Nb on the cracking, grain size, and texture in the as-built material. Mechanical compression testing showed significant improvement in ductility with increasing Nb content. The low concentrations of Nb used did not induce large changes in the yield strength …

Design And Production Of A Carbon Fiber Longboard, Julia H. Stradinger

Honors Theses

This thesis contains an overview of the design, prototyping, and manufacturing of a carbon fiber long board. The purpose of this capstone was to create a viable product for the real-world market and then determine how to manufacture it at scale with sustainable financial practices. In order to accomplish this task, engineering, accounting, and manufacturing challenges had to be overcome throughout all stages. The production process involved the carbon fiber layup, baking, water jet cutting, and assembly of the carbon fiber longboard. In order to optimize this process, continuous improvement and lean manufacturing problem solving techniques were applied. After a …

Manufacturing Process Of A Wooden Tortilla Press: Idea To Production, Olivia R. Marque

Honors Theses

The purpose of this thesis is to document the design, development, and manufacturing of a wooden tortilla press completed as a capstone project through the Center for Manufacturing Excellence (CME). Following the technical details of this thesis is a personal reflection by one team member, Olivia Marque. The project follows a structured product development process that begins with problem definition and concept development, progresses through design, prototyping, and jig fabrication, and culminates in a full production run on the CME shop floor. A multidisciplinary team, including engineers, a marketer, and an accountant, collaborates throughout the project to support both technical …

Manufacturing Of A Wooden Tortilla Press: Idea To Production, Glenn H. Walker

Honors Theses

The purpose of this thesis is to document the design, development, and manufacturing of a wooden tortilla press completed as a capstone project through the Center for Manufacturing Excellence (CME). The project follows a structured product development process that began with problem definition and concept development, progressed through design, prototyping, and jig fabrication, and culminated in a full production run on the CME shop floor. A multidisciplinary team, including engineers, a marketer, and an accountant, collaborated throughout the project to support both technical development and manufacturing execution. Project planning and scheduling were established early and maintained throughout the project to …

Design And Development Of A Manufacturing Process For A Raised Planter Box, Weslyn Mcmurrin, Larson Looney, Haneef Adebisi, Rachel Hipskind, Carolyn Hale

Honors Theses

This report presents the design and manufacturing process of a raised garden bed box with an integrated irrigation system. The goal of this project was to replicate a manufacturing environment in the creation of a durable, ergonomic, and cost-effective product. The project began in Spring 2025 with initial market and financial research to determine design requirements and materials for prototype development and continued through the end of the Fall 2025 semester with a small-scale production run and team presentation. Following our market and financial research, multiple design concepts were evaluated and refined through the use of computer-aided design and prototype …

Manufacturing Process Of A Wooden Tortilla Press: Idea To Production, Colleen Nolan, Ben Bird, Olivia Marque, Emma Palmer, Hayden Walker

Honors Theses

The purpose of this thesis is to document the design, development, and manufacturing of a wooden tortilla press completed as a capstone project through the Center for Manufacturing Excellence (CME). The project follows a structured product development process that began with problem definition and concept development, progressed through design, prototyping, and jig fabrication, and culminated in a full production run on the CME shop floor. A multidisciplinary team, including engineers, a marketer, and an accountant, collaborated throughout the project to support both technical development and manufacturing execution. Project planning and scheduling were established early and maintained throughout the project to …

The Design And Manufacturing Process Of The Concealed Shelf, Joshua Harvel

Honors Theses

The Haley Barbour Center for Manufacturing Excellence (CME) at the University of Mississippi challenges students to manufacture a product and put forth a balanced manufacturing line in a senior capstone project. The chosen product was a concealed shelf, or a shelf with a hidden compartment. The team aimed to design a product, formulate a project plan, analyze the market, conduct financial analysis, develop a prototype, establish a manufacturing process, and demonstrate that process in two production runs. The team used tools such as Computer Aided Design (CAD), market surveys, jig creation, and line balancing to accomplish these tasks. After two …

The Design And Manufacturing Process Of The Concealed Shelf, Mary-Del R. Jansen

Honors Theses

The Haley Barbour Center for Manufacturing Excellence (CME) at the University of Mississippi challenges students to manufacture a product and put forth a balanced manufacturing line in a senior capstone project. The chosen product was a concealed shelf, or a shelf with a hidden compartment. The team aimed to design a product, formulate a project plan, analyze the market, conduct financial analysis, develop a prototype, establish a manufacturing process, and demonstrate that process in two production runs. The team used tools such as Computer Aided Design (CAD), market surveys, jig creation, and line balancing to accomplish these tasks. After two …