Manufacturing Commons^™

Micro Mobile Home R3, Roha Y. Ali, Yuka M. Iwashita, Luke C. Douglas, Joshua Q. Le

Mechanical Engineering

Homelessness is an ever-growing issue all around the world. In 2023, over 250,000 or ~40% of all people experiencing homelessness did not have access to shelter spaces in the U.S. [1]. All people have the right to a place where they are safe from violence, crime, and the constant fear that they will be forced out.

Both homeless people and outdoor enthusiasts need a new way to keep themselves and their belongings safe when living outdoors, since existing products do not offer adequate security, portability, or versatility.

2024-2025 Cal Poly Fluid Power Vehicle Competition Team, Jaskaran Singh Hothi, Justin Menzie Lesko, Tristan Kai Crawford, Lucas Rupert Erickson, Diego Velazquez

Mechanical Engineering

The Fluid Power Vehicle Challenge (FPVC) provides an avenue for the exploration of fluid-powered transportation, adhering to regulations set by the National Fluid Power Association (NFPA). This document serves as a roadmap for our team’s research, design, and manufacturing of a vehicle for participation in the FPVC. The team’s journey began with extensive background research, encompassing stakeholder engagement, analysis of existing solutions, and education on fluid power fundamentals. From this information, we decided to focus on enhancing mechatronics systems, improving the transmission, optimizing the mounting, adding a pneumatic element, and improving the efficiency of the hydraulic system of the vehicle …

Design Principles For Robotic-Controlled 3d Printing Of Soft Tissue-Mimicking Materials, Karina Mealey

Master's Theses

Geometrically and physically accurate 3D models are emerging as essential tools for surgeons in pre-operative planning and training, but current methods of producing these models are not sufficient. Existing solutions have downsides such as high costs, long and tedious production times, high complexity resulting in a lack of scalability, or an inability to meet material requirements for accurately simulating human tissue.

The objective of this work is to develop principles for a low-cost, easy-to-use 3D printing system capable of prototyping with soft tissue-mimicking materials. To pursue this goal, a MyCobot280 robot arm was used as the mechanism to explore the …

Automation Of Post Fermentation Must Removal, Grace Hurley, Jakob Spink, Ariel Metscher

Industrial and Manufacturing Engineering

The Harvest Haulers project addresses a critical operational inefficiency at Saucelito Canyon Winery, where post-fermentation must removal from wine barrels was labor-intensive and potentially hazardous. This project aimed to develop a custom forklift attachment that could securely handle Bordeaux and Burgundy barrels, streamline the dumping process, and improve worker safety.

The resulting solution is a forklift-compatible fixture designed to lift, secure, and tilt barrels using a robust combination of a modified aluminum pallet, padded hoop, ratchet straps, and a custom hinge mechanism. The design meets all engineering requirements, including a 600 lb. load capacity, 135° tilt, and a single-operator setup …

Evoque Delivery System Fixture Optimization, Jack Ellis, Florence Duff, Noah Dunsmore, Timothy Hunter, Rafael Castillo

Mechanical Engineering

No abstract provided.

3d Printed Fixed Wing Aircraft Competition, Sidney E. Long, Mitchell Heise, Jack Bride, Daniel Salinas

Mechanical Engineering

Cal State LA and Arlington University, Texas are hosting the same 3D printed, fixed wing aircraft competition for 2025. Cal Poly requires a competitive plane that can adhere to each rule and be piloted remotely to achieve the longest time in the air. The plane must utilize solely 3D printing technology for the wings, body, and all other structures. The only off-the-shelf components can be the motor and electronics, as well as mechanical devices such as hinges.

Combustion Liner Optimization, William Weeks, Daniel Reed, Isaac Trull

Mechanical Engineering

Solar Turbines provides gas power generation solutions, focusing on gas turbine engines and compressors. The Gas Turbine Products Engineering (GTPE) team at Solar Turbines needs a way to efficiently and cost-effectively maintain the combustion liner of the Taurus model gas turbine at or below the cold-side temperature target. The current system involves a manufacturing process with ergonomic concerns and uncertain cooling effectiveness.

To address this, our team proposed a new combustion liner system featuring impingement cooling. We provided Solar Turbines with heat transfer models of both the existing and proposed designs, demonstrating improved cooling performance. Additionally, a prototype of the …

Adaptive Riding Mount Block, Lucas R. Reynolds, Lukas M. Moreau, Patrick J. Michael, Jandre D. Lafradez

Mechanical Engineering

Professor Sarah Stewart from the Animal Science Department at Cal Poly seeks to develop a solution to help people with disabilities mount horses. Users need a mounting block that can bring them closer to the horse’s back to ease mounting. The current system, consisting of two plastic two-step blocks, is inadequate—unstable, too small, and inaccessible for wheelchair users.

The required solution must meet several key specifications: it should accommodate at least three people standing side by side, be sturdy enough to support their combined weight, and remain stable on rugged terrain like gravel or sand without tilting or sinking. Additionally, …

Lidss Raft Battery Pack Integration, Jack Maxwell, Vincent Stevens, Matthew Hoodmaker, Colin Flanders

Mechanical Engineering

Lawrence Livermore National Laboratory is a critical member of the United States Department of Defense. Their Independent Diagnostics Scoring System (LIDSS) uses rafts that operate in the ocean to collect missile test data. Several times a year, the United States will test their Inter-Continental Ballistic Missiles by launching them into the ocean near the Marshall Islands. This is where the LIDSS rafts collect their test data. Our project was centered around re-designing the battery pack used by the rafts. The current battery pack design experiences water ingress problems and is difficult to access. Our re-designed battery pack is waterproof to …

Comparative Study Of Experimental And Fea Strain Data For Cnt-Coated Fiberglass Sensors, Extensometers, And Metal Foil Strain Gauges, Omar Dwidar

Master's Theses

Material testing is essential across industries such as aerospace, automotive, and construction, playing a critical role in verifying material selection, diagnosing failures, and understanding the development of flaws in structures. These insights are key to designing successful, reliable systems. Conventional metal foil strain gauges are low cost and reliable but provide limited sensitivity with a typical gauge factor around 2. Extensometers provide highly sensitive strain measurements with the disadvantage of a bulky form factor. With advanced materials such as carbon nanotubes, it is possible to manufacture a sensor with the sensitivity closer to that of an extensometer with the small …

Effect Of Manufacturing And Machining Process On Recycled Composite Connecting Rods Under Tension And Compression, Walter W. Oppelt

Master's Theses

Carbon fiber reinforced polymer (CFRP) is an engineering material renowned for its high-strength and low-density material properties. Such properties make CFRPs especially useful for applications across many industries, including aerospace, automotive, marine, sporting goods, oil and gas, and more. However, with such favorable material properties comes the cost of high energy usage required to produce raw carbon fiber. Recycled carbon fiber (rCF) has emerged as a promising alternative, offering a significant reduction in energy usage. This research explores the viability of applying recycled CFRPs to internal combustion engines to both reduce energy costs during manufacturing and while in use. Mechanical …

Surface Resistivity Correlation To Nano-Defects In Laser Powder Bed Fused Molybdenum (Mo)-Silicon Carbide (Sic) Alloys, Andrew Mason, Larry W. Burggraf, Ryan A. Kemnitz, Nate Ellsworth

Faculty Publications

The integration of Silicon Carbide (SiC) nanoparticles into Laser Powder Bed Fusion (LB-PBF) Molybdenum (Mo) printing represents a significant advancement in refractory metal additive manufacturing. Our investigation examined how varying SiC nanoparticle sizes affect the microstructural and electrical properties of LB-PBF-printed molybdenum components while maintaining a 0.01 mass fraction of Mo. At an Linear Energy Densities (LED) of 1.8 J/mm, the addition of 80 nm SiC particles achieved a 46% reduction in porosity, while sheet resistance decreased by 6% at LED of 2.0 J/mm with 80 nm SiC particles. These performance improvements stem from several mechanisms: SiC particles serve as …

Passive Vibration Isolation Systems For Mitigating Rotational Forces In Football Helmet Impacts, Julian Lee

LSU Master's Theses

Helmets have been used for centuries to mitigate head injuries, evolving with advancements in materials and design. They are critical in athletics, construction, and military applications, where shock and vibration isolation play a key role in head protection. Helmet performance is currently rated using the Head Injury Criterion (HIC) and Helmet Performance Score (HPS) metrics. HIC is a metric used in sports and automotive industries which focuses on the probability of injury occurring due to the magnitude and duration of linear acceleration of the head [1]. The HPS metric was created by using a linear combination of HIC and a …

Using Predictive Analytics To Reduce Small Business Cost Estimation Error, Diana Solt

Journal of Applied Packaging Research

Small and medium packaging companies generally employ the use of custom-developed quoting programs to bid goods and services. Custom bid programs (e.g. Excel) are used to capture the company-specific costs of production. The inputs of variable costs, such as machine rate and scrap rate, are critical to get correct; however, companies often rely on educated guesses and industry expertise to quote packaging products to end-users. Due to the guesswork involved there can be a financial difference between the quoted costs and actual costs. This variance is often the cause of significant lost dollars. Price, if not determined correctly, could negatively …

Experimental Characterisation Of Laser Cladding Of Crniw And Crnifealzr Powders On H13 Tool Steel And Optimisation Of Process Parameters, Martin Vinoth S

Theses and Dissertations

In this work, laser cladding on H13 steel substrate with two different powder compositions CrNiW and CrNiFeAlZr has been carried out. The laser power, powder feed rate, and scanning speed were varied and the clad dimensions, aspect ratio, and dilution percentage were measured. The microhardness found in the CrNiW clad is 834 ± 20 HV0.5, which is higher than that of the CrNiFeAlZr clad (780 ± 20 HV0.5) as well as the substrate (548 ± 20 HV0.5).

The X-ray Diffraction (XRD) patterns identified the common phase creation of Ni3C and Fe3C for CrNiFeAlZr and CrNiW coatings, while the oxide formation …

A Product Development Process From Concept To Production: Smartphone Projector, Ross G. Cohen, Piper G. Thomas

Honors Theses

The purpose of this thesis is to demonstrate the production and documentation of the SmartPhone Projector Capstone for the Center of Manufacturing Excellence (CME). This document follows the production development from the beginning Spring 2024 problem definition all the way to the Fall of 2024 final product. This project was completed by a team of five undergraduate students, including an accounting major, finance major, biomedical engineering major, and two mechanical engineering majors. The goal of this project was to design and build a SmartPhone projector, then carry out a full production run located on the CME shop floor. To begin …

From Concept To Light: Manufacturing A Dual-Purpose Bedside Lamp And Book Organizer, Nicole Goulet

Honors Theses

This report features the design, development, engineering changes, and manufacturing of the Bedside Lamp, a hand-made multi-purpose lamp, book holder, and charging hub. The investigation began with research and a market analysis on current lamp designs and a discussion about what features would set the lamp apart. This led to the design of the lamp and construction of multiple prototypes for proof of concept.

A manufacturing process was then designed to demonstrate the steps to start up an efficient and cost-effective production line. This process included obtaining raw materials, cutting them into the necessary parts, and assembling everything to create …

Exploring Manufacturing Techniques For Small-Scale Metal Fabrication And How They Can Be Optimized For Efficiency, Precision, And Scalability To Produce A Fire Pit, Henry W. Potter

Honors Theses

This thesis explores manufacturing techniques for small-scale metal fabrication, using a fire pit production as a case study to optimize efficiency, precision, and scalability. The study examines the challenges of small-scale manufacturing and analyzes alternative manufacturing techniques for cutting, joining, and surface finishing. Data was gathered through a case study involving the design and production of a fire pit. The manufacturing process included cutting, rolling, joining, and surface finishing. Alternative techniques, such as laser cutting and a paint sprayer, were compared to the methods used in the project. It was concluded that alternate methods offered improvements in efficiency, precision, and …

Mechanical Engineering Senior Design Capstone Modine Engineering: Collapsible Hvac Coil Expansion Table, Austin M. Hipskind

Honors Theses

For the Mechanical Engineering Senior Design class, teams of seniors were asked to find a sponsor company willing to provide a problem they were experiencing at a local plant. Using the skills gained throughout college, they were asked to go through a standardized problem-solving method to develop a solution for the sponsor company. I was teamed with Fernando Arellano and Henry Lindsey to work with Modine Engineering on creating a modular and collapsible table for use with large, custom-designed coils. This table would have to hold large, heavy coils during the expansion process. Modine requested a 3D design, the cost …

Computational Modeling Of Torque Arm And Load Cell Interactions In Uta Racing Brake Dynamometer, Anthony A. Aiyedun

2025 Spring Honors Capstone Projects - Archive

The UTA Racing Team is developing a brake dynamometer to measure the coefficients of friction of various brake pads and calipers under controlled conditions. The dynamometer simulates on-track braking scenarios, testing brake pads at temperatures up to 1300ºF and pressures similar to racing environments. Its primary goal is to generate accurate friction vs. temperature graphs for various brake pad and rotor combinations, addressing the need for dedicated testing equipment. This project creates an ANSYS simulation of the torque arm and load cell interaction. The computational model accurately represents the relationship between applied torque and measured load cell force, incorporating precise …