Manufacturing Commons^™

Designed Extrudate For Additive Manufacturing Of Zirconium Diboride By Ceramic On-Demand Extrusion, Devin Mcmillen, Wenbin Li, Ming-Chuan Leu, Greg Hilmas, Jeremy Lee Watts

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This work describes a process by which zirconium diboride (ZrB2) parts may be fabricated using the Ceramic On-Demand Extrusion (CODE) process. An oxide-carbide-nitride system consisting of ceramic powders and pre-ceramic organics, designed to yield ZrB₂ after reaction sintering, has been developed to produce an aqueous-based extrudate for subsequent processing in the CODE system. Pressurelessly sintered test specimens containing 1 wt% PVA binder achieve high relative density ≥ 99%. The viscoelastic response of the extrudate was characterized via spindle rheometry with a small sample adapter. Batches with 1 wt% PVA and 0.5 wt% Methocel show strong shear thinning characteristic, under …

Effects Of Build Parameters On Compression Properties For Ultem 9085 Parts By Fused Deposition Modeling, Krishna P. Motaparti, Gregory Taylor, Ming-Chuan Leu, K. Chandrashekhara, James Castle, Mike Matlack

Mechanical and Aerospace Engineering Faculty Research & Creative Works

It has been observed by various researchers that parts fabricated by the Fused Deposition Modeling (FDM) process have anisotropic properties. The research presented in the present paper was aimed to study the compression properties of FDM parts and to comprehend their dependence on build parameters. In this study Ultem 9085 was used as the material to fabricate both solid and sparse-build coupons with variations in build direction, raster angle and air gap. A full factorial experimental design was used to study the individual and combined effects of these build parameters on the mechanical properties of the coupons. The mechanical properties …

Proposed Hybrid Processes For Part Building Using Fusion Welding And Friction Stir Processing, Megan A. Gegesky, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

It has been shown that a hybrid laser additive manufacturing and friction stir processing can deposit components with forged-like structures. This paper reports a hybrid fusion welding and friction stir process to create parts with quality structures. Combining traditional fusion welding and friction stir processing techniques for non-weldable aluminum alloys could facilitate the joining of difficult geometries in manufactured parts. This research illustrates mechanical property changes for non-weldable and weldable aluminum alloys. The Vickers hardness, and microhardness in the case of AA5052-H32, tensile strength and corrosion resistance of four processing states: base material, fusion welded material, friction stir welded material, …

Determining The Print Accuracy Of Four Three-Dimensional Printers, Kshiteej Dalal

Master of Technology Management Plan II Graduate Projects

Rapid prototyping [RP] or 3D printing [3DP] have existed for some time now. One of the major deficiencies of 3DP is the accuracy of the printed three dimensional parts. Even beyond that is the lack of studies that have been designed to measure the 3DP components. Measuring, verifying and determining the accuracy of 3DP parts is the focus of this study. As the accuracy is measured and approaches those of CNC machined parts, it will drive the development of additional additive manufacturing [AM] machinery. In this project a component is created in a solid modeling package. A solid model of …

Laser-Assisted Microchanneling On Pmma Substrate Utilizing Two-Pass Fabrication Method, Sijie Zhang, Yung C. Shin

The Summer Undergraduate Research Fellowship (SURF) Symposium

Microchannel is widely used in microfluidic devices for mixing, chemical reaction, detection, particle separation and etc. CO₂ laser-based microchanneling of PMMA as a low cost, rapid, noncontact fabrication method has attracted the attention of industry. However, the typical V-shape grooves fabricated by CO₂ laser microchanneling have limitations since the V-shape grooves will affect the flow behavior and heat transfer of the fluid, which are important to the performance of microfluidic devices. A two-pass fabrication method is proposed and investigated in this paper to improve the quality of the PMMA microchannel fabricated by CO₂ laser. It was found …

Laser Assisted Manufacturing: A Comparison Of Mechanical Properties Between Lam And Conventional Manufacturing Techniques, William Blakeslee, Neil S. Bailey, Kyung-Min Hong, Shunyu Liu, Yung C. Shin

The Summer Undergraduate Research Fellowship (SURF) Symposium

Laser assisted manufacturing methods, such as direct metal deposition (DMD) and laser beam welding (LBW), are promising methods because of their higher precision and greater productivity when compared to traditional manufacturing methods. Because these methods are relatively new, the mechanical properties of samples produced by laser assisted manufacturing are not well understood. In this study the mechanical properties of samples produced by laser assisted manufacturing methods are analyzed and compared with data obtained from traditional manufacturing methods. The DMD process used Fe-TiC and Ti-TiC metal matrix composites, while LBW used AISI 304 stainless steel. The results vary widely with the …

Applications Of Additive Manufacturing Techniques In Making Energetic Materials, Peter A. Cattani, Trevor J. Fleck, Jeff F. Rhoads, Steven F. Son, I. Emre Gunduz

The Summer Undergraduate Research Fellowship (SURF) Symposium

Energetic materials are currently manufactured using methods such as casting, which can only produce certain geometries. Additive manufacturing enables more flexible fabrication and the potential for improved material consistency. Additive manufacturing has transformed many industries, but has only recently been applied to the manufacturing of energetic materials. This paper describes the development of two processes to apply additive manufacturing methods to energetic materials. Method one applies a fused deposition modelling approach (FDM). 5 µm aluminum powder and PVDF were mixed and made into filaments using a Filabot Original filament extruder. Energetic filaments were created composed of 90:10, 80:20, and 75:25 …

Design For Manufacturability: Off-Road Toyota Bumper, Drew Donlon

Industrial and Manufacturing Engineering

The purpose of this project is to design a new off-road bumper that is improved from the stock form of a 1996-2002 Toyota 4Runner and a 1996-2004 Toyota Tacoma. The current state of the component is too weak to endure to off-road endeavors, and a kit bumper market is virtually untapped for these vehicles. The objectives of this project were met by redesigning the stock front bumper, conducting a finite element analysis on the model to test for strength, prototyping the bumper with CNC cut cardboard, and conducting a full cost analysis including the costs for waterjet and laser cutting …

Evolution Of The Automotive Body Coating Process—A Review, Nelson K. Akafuah, Sadegh Poozesh, Ahmad Salaimeh, Gabriela Patrick, Kevin Lawler, Kozo Saito

Mechanical Engineering Faculty Publications

Automotive coatings and the processes used to coat automobile surfaces exemplify the avant-garde of technologies that are capable of producing durable surfaces, exceeding customers’ expectations of appearance, maximizing efficiency, and meeting environmental regulations. These accomplishments are rooted in 100 years of experience, trial-and-error approaches, technique and technology advancements, and theoretical assessments. Because of advancements directed at understanding the how, why, when, and where of automobile coatings, the progress in controlling droplets and their deposition attributes, and the development of new technologies and paint chemistries, a comprehensive and up-to-date review of automobile coatings and coating technologies was considered to be of …

Gold Contamination In Non-Lead Surface Mount Solder Joints, Richard Alexander Garrison

Industrial and Manufacturing Engineering

Abstract

Solder joints are critical to the reliability of circuit boards. If gold is introduced to the solder joint, brittle AuSn4 intermetallic compounds develop which affect reliability of that solder joint. To determine the effects of gold when dissolved into a non-lead solder joint, a process was developed in order to apply gold content onto SAC305 solder paste. The gold was transferred as a paste from a micropipette onto each individual solder bump. This process was designed to apply a range of gold content from 1.0 wt. % to 10 wt. % to each individual solder joint. The test board …

Improving The Mechanical Performance Of 3d Printed Parts Using Fused Filament Fabrication, Inderpreet Binning

Industrial and Manufacturing Engineering

The 3D printing industry has seen rapid growth in the last 10 years and has been called the next industrial revolution. There are several different processes used in 3D printing, but the most popular process is called Fused Filament Fabrication (FFF) or Fused Deposition Modeling (FDM). This is the process where (most commonly) plastic filament enters a nozzle, is heated to a semi-liquid state, and then deposited into a pattern to create a print. One major drawback to this process is that the prints are anisotropic. This means that the strength of the print varies with the orientation that it …

Design & Analysis Of A Bicycle Towing Device, Austin Lynch, William Max Mcewan, Fredrik Stenson

Industrial and Manufacturing Engineering

A local businessman had the idea to build a device that allows a bicycle to tow another bicycle. He built a prototype to demonstrate his idea but he wanted help in developing a product that could fit more bikes, did not require a rear rack to operate, and be manufacturable at his facility. He also expressed interest in an economic evaluation of production and marketing of the device. An analysis of customer needs led to adding reduction of weight and ease of attachment to the design requirements.

This report is about improving the original design and presents the process of …

Haas Automation Umc750 5axis Mill Assembly Process Improvement, Mason A. Garcia, Gregory R. Gunion, Juan Pablo Quinonez Weston

Industrial and Manufacturing Engineering

The improvement of the current assembly of the motor and casting components for the Haas UMC-750 5-Axis vertical CNC mill includes the evaluation, development and proposal of a new pair of material handling carts. To meet these deliverables, a student team began by assessing the assembly workstation, defining the problem to be solved, researching ergonomics in material handling equipment and drafting the final design of the improved cart models using SolidWorks. The final design considered the initial improvement request from the client, as well as better ergonomic features to enhance the safety of the operators. It was estimated that the …

Mentoring Management Database, Alexandra Cava, Samantha Kin

Industrial and Manufacturing Engineering

A new mentoring program is set to begin next year pairing children from Kindergarten through 12th grade with college students as their mentors. Keeping track of the mentor information, mentee information, pairings, stipend disbursements, interview question results, events, and final assessments by hand would be extremely difficult, therefore, a database would be a great asset to the program.

Creating a database in Microsoft Access allows a user to have all this information in one convenient location, therefore, ensuring there is a good user interface is a key component to this project. Using Perach’s "Guide to the Perplexed" as the base …

E-Learning Design For Microsoft Access & Asp.Net, Jonathan Choi, Christopher Hom

Industrial and Manufacturing Engineering

The problem definition is that the current video tutorial series is outdated and lacks interactive features that aid with E-Learning. The goal of the project is to create a platform that incorporates features such as structure, interaction, assessments, and competency tests. The project revolved around integrating four softwares together in order to create an effective E-Learning platform. The four softwares were Adobe Captivate, Camtasia, Microsoft Access and Microsoft Visual Studios. Adobe Captive is used to store the tutorial video and assign quizzes. Camtasia is used to record the tutorial videos. Microsoft Access is used to store all the questions given …

Smart Packing With Qr - Improving Cal Poly's Parking System For All Users, Kelsey Bazshushtari, Andrew Lee, Christopher Ragasa

Industrial and Manufacturing Engineering

Cal Poly Smart Parking, herein referred to as CPSP QR Code Initiative, is developed to reduce the wait times student, staff, and guest drivers experience when searching for a parking spot on campus. Cal Poly is currently undergoing a large growth in student population, and, as a result, is experiencing congestion in parking lots. Drivers will commonly spend frustrating amounts of time "vulturing" these parking lots for an open spot. CPSP QR Code Initiative consists of a database that is controlled by user submitted data through QR codes scanned on a user’s smartphone. This system will provide drivers with a …

Soto's True Earth Market Optimization, Hironari Fujita, Wei Lin Luong, Sean Macwilliams

Industrial and Manufacturing Engineering

Soto’s True Earth Market is a new organic market startup which is located in a historical facility in the small town of Cambria. The new owner of Soto’s Andre Ponce has a vision to create a community revolved around local organic foods and sustainability. Since Soto’s is still in the initial startup phase there is a large amount of room for optimization and redesign in order to create a solid customer foundation. Andre presented several opportunities for improvement to the team. With a time constraint of solely two quarters the project team decided to provide the following:

● Old and …

Building A Startup Wine Brand, Sean Christopher Silvestre

Industrial and Manufacturing Engineering

Lisso Wine is a company that currently purchases wine from a California winemaker and resells it in China. In order to reach more customers and increase sales, Lisso wants to create their own brand of wine while keeping the winemaker as a supplier. However, they do not have a plan for the marketing, production, or distribution of their new product. This project will be treated as a startup venture by Lisso Wine and designed to be operated by a handful of people with limited resources. Sustainable and cost-effective materials were selected for the product and it’s packaging in order to …

Inventory Tracking Software Improvement Project, Jacky Leung

Industrial and Manufacturing Engineering

FanimeCon’s Convention Operations department required standardized processes and controls for their inventory tracking software. On top of the current web application, new controls were put into place for checkout limitations. To allow for a continuous improvement effort, processes became standardized with a new graphical user interface where user input is recorded. These will provide processing times for further study in proposing redesigned layouts and more efficient processes.

National Society Of Sales Engineers & National Sales Engineering Competition, Joseph Lynes, Tyler Sasse

Industrial and Manufacturing Engineering

Sales Engineering is a popular career choice for many engineers coming out of university. Despite its continuing growth, many students lack the knowledge and preparation to be successful in the early years of their career. A small collection of sales engineering minors and student clubs are the only option for students interested in technical sales.

Using the DMAIC process, the senior project team went step by step to find and implement the best possible solution to better connect college students and the professional sales engineering industry . The team worked side by side with professionals in the industry and students …