Structures and Materials Commons^™

Smart Process Planning For Automated Fiber Placement, Matthew J. Godbold

All Dissertations

Automated Fiber Placement (AFP) is a preeminent manufacturing technology for producing high-performance composite structures, offering precise material placement, reduced waste, and the potential for highly optimized lightweight designs. While AFP has been widely adopted in aerospace applications, its broader use across industries such as automotive, wind energy, maritime, and sporting goods remains limited. A key barrier to wider adoption is the traditional separation of design, manufacturing, and inspection processes, which drives up cost and results in inefficiencies, sub-optimal designs, and limited feedback between lifecycle stages. In current practice, manufacturing is treated as an isolated process, disconnected from early-stage design decisions …

Direct Ink Writing Of Functional Fiber/Granular Composites, Zhuoyuan Yang

Doctoral Dissertations and Master's Theses

Direct ink writing provides a versatile manufacturing route for fabricating functional fiber and granular composites with controlled architecture, tunable interfaces, and customized material distributions. Fiber reinforced composites offer high stiffness, strength, fatigue resistance, and functional anisotropy, while granular composites provide scalable access to particle based structures with high material efficiency and broad resource compatibility. However, the additive manufacturing of these composite systems remains challenging. For fiber based composites, precise control of fiber placement, matrix impregnation, interfacial bonding, and freestanding deposition is difficult to achieve during printing. For granular composites, stable particle flow, controllable packing, binder infiltration, and shape retention are …

Cohesive Zone Modelling Of Fiber–Matrix Interface In Composite Materials, Arjun Myadam

Doctoral Dissertations and Master's Theses

Carbon Fiber reinforced polymers (CFRPs) are widely used in aerospace, automotive, and structural applications due to their high specific strength, stiffness, and design flexibility. Their mechanical performance is critically governed by the fiber–matrix interface which controls stress transfer and directly influences damage initiation, crack propagation, and fracture behaviour. The interface properties are quantified through the Interfacial Shear Strength (IFSS) and fracture energy, both serving as key indicators of composite integrity. Effective interfacial bonding is therefore essential to the composite’s strength. Nanoscale fiber surface modifications provide a promising approach to enhance interfacial bonding and can also impart multifunctionality. These multifunctionalities can …

Advancing Sensing And Structural Health Monitoring Of Non-Conventional Space Structures, Scott Bender

Doctoral Dissertations and Master's Theses

Future lunar and deep-space missions will require new structural concepts that reduce mass while maintaining reliability. Two technologies that have received significant attention are inflatable habitats and additively manufactured structures; however, challenges remain in their characterization, validation, and long-term monitoring. This dissertation investigates methods to improve the testing and sensing of these non-conventional aerospace structures through the use of advanced photogrammetry and embedded distributed fiber-optic sensors. A color-filtering digital image correlation technique was developed to isolate orthogonal strain directions in woven inflatable structures, providing improved characterization of biaxially loaded softgoods. In addition, methods were developed to embed distributed fiber-optic sensors …

Mars Rover Wheels And Drive, Presley S. Sacavitch, Ryan W. Trevena, Dylan A. Mack, Daniel Hudak

Mechanical Engineering

Cal Poly’s Poly1Rover team, advised by Professor Rich Murray, aims to deploy four student-designed mini-Mars rovers, each equipped with a sample-tube retrieval claw, before 2030. However, the wheels of Poly1Rover’s current 6th generation rover are not ready for deployment to Mars, as they do not utilize space-grade materials, are not optimized for manufacturability, and lack sufficient spoke compliance to absorb landing and high-impact loads. This project will be developed by a team of Mechanical Engineering students at California Polytechnic State University, San Luis Obispo (Cal Poly): Daniel Hudak, Dylan Mack, Presley Sacavitch, and Ryan Trevena. Next Intent is providing funding …

Improving The Reliability And Performance Of A Supersonic Indraft Tube Wind Tunnel, Christian J. Kaml

Master's Theses

Access to supersonic testing is increasing in demand, and wind tunnels remain one of the safest and most cost-effective methods for gathering high-speed flow data. Despite being more economical than alternative options, supersonic wind tunnel facilities often require substantial investment to construct, operate, and maintain.

The novel indraft tube tunnel architecture was conceived as a high-speed flow testbed that incorporates features of both Ludwieg tubes and indraft wind tunnels to maintain costs low enough to be accessible even to small universities. This design was first developed and tested in 2018 at California Polytechnic State University, featuring a cost per test …

Effects Of Atomic Oxygen Exposure On Stressed Drag Sail Materials For Low Earth Orbit Applications, Nazanin Sadeghian Dezaki

Master's Theses

As low Earth orbit (LEO) has become an increasingly valuable region for satellite operations, it has grown increasingly congested. The Federal Communications Commission (FCC) deorbit regulations require satellites to be deorbited within 5 years of launch, and drag sails represent a practical means of meeting this requirement. An important consideration for drag sail design is the effect of atomic oxygen (AO) on sail materials. To address the gap in the literature regarding the behavior of stressed drag sail materials under AO exposure, a new test plate was manufactured for the California Polytechnic State University minimum atmospheric experimentation (MAX) AO chamber. …

Hamster: Hybrid-Actuated Mobile Spherical Terrain Exploration Rover, Winnie Gao

Master's Theses

The expansion of space exploration to increasingly challenging planetary environments requires mobility systems capable of extreme traversal capabilities and operational reliability. This thesis presents the design, development, and testing of a low-cost Hybrid-Actuated Mobile Spherical Terrain Exploration Rover (HAMSTER) intended for use on a planetary surface exploration mission. HAMSTER uses a pendulum-based actuation method for steering and an actuated internal shaft to propel the vehicle forward. The internal structure includes a two-tiered central case composed of the navigation control module, accelerometer, motor controller, primary DC motor, battery, voltage regulators, Raspberry Pi, pendulum servo motor, and drive shafts. Additive manufacturing through …

Sentience, Sheetal Agrawal

Masters Theses

The increasing urgency for sustainable and adaptive systems has driven research toward embedding intelligence directly into materials rather than relying solely on external sensing and control systems. This thesis explores how smart material1 embedded systems can be designed to recognize and respond to environmental signatures, defined as measurable patterns such as temperature fluctuations and mechanical forces. Central to this investigation is the integration of shape memory alloys, particularly Nitinol, with geometry-based actuation mechanisms that amplify material behavior into functional system responses.

The central argument is that designing with smart materials is a design problem, not primarily a materials science problem …

Lunar Regolith Sintered Brick Apparatus, Andrew Fasano, Noah Parayil, Darius Felix Karra

Senior Design Project For Engineers

This project describes the preliminary design and analysis of the Semi-Autonomous Lunar Regolith Sintered Brick Apparatus that will assist in developing permanent infrastructure on the Moon. An issue with permanent lunar operations is the transportation of materials to the Moon. To address this, the designed device uses lunar regolith as the source material for producing bricks. This design considers the constraints set for operation with the Griffin lunar lander: maximum payload mass of 200 kg, power consumption below 5 kW, and limited payload dimensions. The design uses a combination of a laser sintering motion system, a regolith layering subsystem, a …

Stabilized Cargo Relay Aircraft For Precision Payload Yielding, Dato A. Tabidze, Michael Conely, Ben Courtney

Senior Design Project For Engineers

As military missions become more complicated, warfighters need more capable drones to use across diverse scenarios. The same also applies to civilian applications, like infrastructure inspection, package delivery, and disaster response. Current multirotor drones, also known as unmanned aircraft systems (UAS), provide simplicity, affordability, and ease of operation; however, their primary limitation is their low payload-to-weight ratio, which typically falls at 1:1 or less. The DARPA Lift Challenge aims to shatter the heavy lift bottleneck, seeking novel drone designs that can carry payloads more than four times their weight, which would revolutionize the way we use drones across all sectors. …

Experimental Investigation Of Mode-Ii Interlaminar Fatigue Damage In Stitched And Unstitched End-Notched Flexure Carbon Fiber Composites, Madelyn Sloan Berry

Honors Theses

Composite materials are increasingly used in aerospace structures due to their high strength-to-weight ratio, but their susceptibility to interlaminar fatigue damage remains a critical concern, particularly under mode-II shear loading. This study investigates the fatigue behavior of stitched and unstitched quasi-isotropic carbon fiber composite specimens made of SAERTEX Class-75 non-crimp fabrics and Hexcel 1078-1 epoxy via vacuum assisted resin transfer molding. Global fatigue behavior was analyzed using displacement and crack length cycle relationships derived from compliance calibration methods (CCM), while local behavior was examined using digital image correlation (DIC). Unstitched specimens exhibited a single rapid crack growth associated with unstable …

Instrumentation And Control Of A Novel Device To Simulate A Hypersonic Environment, Andrew Marcello

Doctoral Dissertations and Master's Theses

The hypersonic flow regime poses several challenges regarding the design of hypersonic vehicles. Among them is the massive energy and economic expense associated with ground- testing evaluation of material responses within this extreme environment. In order to provide a low-cost, rapid option for preliminary material analysis within hypersonic applications, a novel device is under production to replicate this environment on the surface of these materials. This device has been designed to work in conjunction with Argonne National Laboratory (ANL) Advanced Photo Source (APS) synchrotron, to allow for in-situ characterization of ablation and oxidation on the sample surface.

To achieve this, …

Detecting And Repairing Conflicting Constraints In Co-Trained Physics-Informed Neural Networks For Composite Curing Processes, Cooper J. Evans

Dissertations, Master's Theses and Master's Reports

Composite materials have become a critical component of modern manufacturing, especially in the automotive and aerospace industries. The curing process for these composites has been modeled using a variety of partial differential equations representing the heat transfer and composite curing kinetics. Optimizing the applied temperature profile is critical for maximizing the efficiency and capacity of composite part manufacturers. Constraints must be placed on the inputs and outputs of the model, including but not limited to, the applied temperature profile, part temperature, and final degree of cure. Conflicting sets of constraints are easy to unknowingly impose due to the highly coupled …

Students For The Exploration And Development Of Space (Seds) Air Brake Subsystem: High-Altitude Autonomous Apogee Modulator System For High-Powered Rockets (Haamshr), Camden J. Maclean, Matthew Wharton, Nick Revis, Colin Guido

Honors Theses and Capstones

The objective of this project was to research, design, fabricate, and analyze an autonomous apogee modulation air brake system for the University of New Hampshire (UNH) Students for Exploration and Development of Space (SEDS) high-powered rocket as competitors in the Friends of Amateur Rocketry – Oxidizers Uninhibited Tournament (FAR-OUT) competition.

This air brake system would be developed with considerations for full autonomy, structural reliability, and repeatable deployment. The design would also be easily integrated into the existing high-powered rocket airframe and mechanically simple to increase reliability and practical functionality. The final design would be evaluated using finite element analysis simulation …

Multiphysics Transport In Porous Thermal Protection Systems: Experimental Characterization Of Gas Permeability And Radiative Properties, Yejajul Hakim

Theses and Dissertations--Mechanical and Aerospace Engineering

Porous thermal protection systems (TPS) used in hypersonic vehicles exhibit coupled gas and radiative transport across multiple regimes and length scales. Accurate performance prediction requires reliable characterization of permeability, slip-flow behavior, and radiative transport properties, particularly for low-permeability and charred materials where existing data are limited. This dissertation presents experimental methods for characterizing multiphysics transport in porous TPS materials. A modular flow system was developed to measure permeability and slip behavior in both virgin and charred materials under relevant environments. A transient pressure decay method enables accurate permeability estimation in low-permeability regimes and provides insight into effective pore structure. Results …

Aeroelastic Simulation Of Shape Adaptive Wing, Allan Alfred Kozich Iii

Honors Undergraduate Theses

Morphing wings provide aerodynamic qualities that normal fixed wings cannot, such as the ability to improve endurance yet maintain maneuverability, overcome strong gusts, vibrations, and shocks, and handle both ideal flight for both high and low speeds. A critical application of the new generation of morphing wings is the ability to overcome and affect the onset flutter, a self-excited oscillatory instability that has led to the destruction of aircrafts. This work investigates aeroelastic behavior and measurement of a meta-material structured "smart" wing and its attempt to delay the effect of flutter. The variable wing tip model is analyzed through finite …

Buckling Analysis Of Auxetic Composite Laminates And Optimal Design Using Lamination Parameters And Machine Learning, Hans Bendon Maria Tamil Selvan

Mechanical and Aerospace Engineering Theses

Composite materials are widely used as structural panels in aerospace, automotive, and civil engineering applications, where buckling is often a critical failure mode. This thesis focuses on the analysis and design of composite laminates that maximize buckling performance under prescribed stiffness and thickness constraints.

The first part of the study investigates the buckling behavior of auxetic laminates, which exhibit a negative Poisson's ratio. While previous studies suggest that auxetic laminates can achieve higher critical buckling loads than non-auxetic laminates under simply supported boundary conditions with lateral restraint, the influence of other boundary conditions and plate aspect ratios has not been …

System-Level Assessment Of Non-Ideal Phase Change Material Behavior In Low Earth Orbit Spacecraft Thermal Control Models, Nathan S. Bruursema

Dissertations, Master's Theses and Master's Reports

Phase change materials (PCMs) are of interest in spacecraft thermal control because their latent heat capacity can provide passive thermal buffering during transient or cyclic heat loads. PCM behavior is often treated using idealized assumptions such as repeatable phase transition temperatures, consistent thermal accessibility across cycles, and full latent recovery. However, practical PCM behavior may be affected by non-ideal phenomena such as supercooling, interfacial resistance, and degradation of internal transport accessibility. This thesis examines the system-level relevance of these effects for low Earth orbit (LEO) spacecraft thermal control and identifies the operating conditions under which non-ideal PCM behavior becomes design-relevant. …

Made On Mars: Design And Manufacturing Of Structural Polymer-Regolith Composites, Pailey M. Vitale

Williams Honors College, Honors Research Projects

Human exploration of Mars is constrained by harsh environmental conditions and the prohibitive cost of transporting materials from Earth. Long-term sustainability requires the local production of mechanical and structural components using resources available on Mars, thereby minimizing payload mass. This project investigates polymer–regolith composites derived from atmospheric CO₂ and mineral-rich regolith as a pathway toward in-situ manufacturing. These composites, when compatible with additive manufacturing, could replace imported plastics, enable on-demand fabrication, and support closed-loop recycling systems. The objective is to design and evaluate polymer–regolith composites that maintain mechanical integrity and environmental resistance under Martian conditions, including extreme temperature swings, radiation …

Design New Stage For Vacuum Pin On Disk, Miranda Boyd

Williams Honors College, Honors Research Projects

For my senior design project, I am redesigning the moving stage for the vacuum pin-on-disk test used in the Akron Engineering Tribology Lab. This system is used to evaluate bearings and lubricants for aerospace applications under controlled vacuum conditions. The current stage design limits flexibility when adjusting for different testing parameters, so my goal is to develop a new movable stage that allows for varying weights and loads to be applied accurately and safely. The redesigned stage will improve test efficiency, adaptability, and precision, ensuring the system can accommodate a wider range of experimental conditions and materials while maintaining compatibility …

Breaking The Vapor Barrier And Scale: Revolutionizing Steel Quenching With Ultrasound Technology, Anthony O. Santos

Williams Honors College, Honors Research Projects

The quenching process is a fundamental heat treatment used to enhance material properties by heating steel to its austenitizing temperature and rapidly cooling it to form high-strength martensite. However, this process is often hindered by two surface barriers: the Leidenfrost effect (vapor blanket) and oxide scale. These cooling limitations restrict the use of steel in high-performance aerospace applications due to inconsistent material properties and unpredictable engineering properties. This research investigates the use of fully submersible, 50-watt 40 kHz ultrasound technology to improve cooling rates in a Jominy test [4]. Through numerical simulations and experimental validation, the study demonstrates that acoustic …

Large Telescope Mount For Long Exposure Photos, Payne M. Landis, Anna J. Gray

Williams Honors College, Honors Research Projects

When viewing the stars through a telescope, it is common that the object you are viewing drifts out of view. Many amateur astronomers seek to capture long exposure images of the stars, planets, and galaxies with commercially available sky tracking telescope mounts. The complication is that these telescope mounts are both incredibly expensive and have low weight limits. These issues limit accessibility to these products based on the telescope. For each person, telescope parameters determine the amount of light and magnification that can be viewed, which then determines exposures time for adequate photo results. The options on the market for …

Optimization Of Post-Processing Methods For Additively Manufactured Metals, Julia R. Carano

Williams Honors College, Honors Research Projects

Ultrasonic Nanocrystal Surface Modification (UNSM) is a process used to change the surface hardness of flat-faced materials. It is a machining process using a high-powered laser and a blunt-tipped tool at high speeds which aims to improve the uniformity of the surface on most metals. By heating and pressing the surface of the workpiece, the grains of the material become less rounded and more cohesive on a microscopic level. This, ideally, results in a workpiece with improved material properties. The changes were previously observed through hardness testing.

Thermal Radiation Effects On Particles From Plasma Arc Radiation, Reece Davis, Joseph Mcgee

Williams Honors College, Honors Research Projects

Understanding the radiation heating and transport of both microparticles and nanoparticles is a phenomenon that is critical for both space and Earth sciences. In space, these particles are heated by plasma arcs within ionized space clouds or solar flares and can be present the path of deep space missions and orbital satellites. While on Earth, processes such as forest fires, nuclear fusion, and microchip manufacturing include the plasma arc heating of particles. These particles lay within the Mie Scattering Regime and Rayleigh Scattering Regime and emit radiation differently based on their diameter. New mathematical and computational modeling has been conducted …

Predictive Structural Modeling In Ansys And Destructive Testing For Composite Structures, Dylan Matthews, Grant Abraham, Andrew Raineri

Williams Honors College, Honors Research Projects

Composite structures are central to the performance and reliability of Zips Racing’s Formula SAE vehicles, yet the team currently relies on historical data and partially unvalidated assumptions when selecting carbon fiber layups. This project aims to establish a quantitative, experimentally validated framework for designing composite components through the integration of simulation modeling, physical fabrication, and destructive mechanical testing. Analytical laminate theory models developed in MATLAB and laminate simulations created in Ansys ACP will be used to predict stiffness, strength, and failure characteristics for a range of candidate layups. These predictions will be validated through controlled testing of fabricated composite coupons …

Automated Soil Resetting System For Extraterrestrial Regolith Simulation, Parker W. Brennan, Anthony C. Daniels

Williams Honors College, Honors Research Projects

This project focuses on designing an automated soil resetting system for extraterrestrial regolith simulation. The system will prepare a regolith simulant testbed to a desired, repeatable density, enabling reliable wheel–terrain testing for planetary rover research. Manual soil preparation currently exposes testers to hazardous particulates and produces inconsistent results.

The proposed system will integrate mechanical and control elements to reset the soil bed safely and efficiently. A combination of raking and vibrational methods will be explored, with feedback sensors and automation to achieve target density control. The research will proceed through literature review, benchtop experimentation, prototype design, and full-scale testing over …

Fused Filament Fabrication Additive Manufacturing Of 17-4 Ph Stainless Steel: Process–Structure–Property Relationships In Magnetic Materials, Maanav Patel

Theses and Dissertations

Additive manufacturing (AM) enables the fabrication of complex metallic components through layer-by-layer processing directly from digital models. Among AM techniques, material extrusion–based processes such as fused filament fabrication (FFF) provide an accessible method for producing metal parts using filament feedstocks composed of metal powders and polymer binders. When applied to precipitation-hardening stainless steels such as 17-4 PH, the processing route and heat treatments can influence the resulting microstructure and functional properties. This work investigates the magnetic behavior of 17-4 PH stainless steel fabricated using FFF and evaluates how heat treatment conditions influence measured magnetic properties. Samples were produced and analyzed …

Vibration-Based Control Of Nonlinear Dynamic Systems, Ossyris N. Bury

Honors Undergraduate Theses

This thesis investigates vibration-based stability as a mechanism for achieving self-stabilizing nonlinear dynamic motion in engineered systems. Inspired by biological hovering flight, in which periodic wing motion can passively enhance stability, the study explores how controlled oscillations can be used to stabilize otherwise unstable mechanical configurations. The research centers on a simplified dynamic model based on the Kapitza pendulum, an inverted pendulum with a vertically oscillating base, which serves as a foundation for understanding vibration-induced stabilization. Analytical modeling using Lagrangian mechanics is employed to derive the governing equations of motion and identify the excitation conditions required for stable inverted behavior. …

Structural Batteries For Aerospace Applications, Tariqullah Wardak

Honors Undergraduate Theses

There is increasing pressure on the aviation sector to lower carbon emissions and switch to entirely electric and hybrid propulsion systems. However, the feasibility of standard lithium-ion batteries for long-range aircraft is limited, as they add substantial weight and occupy significant volume. Structural batteries, which combine load-bearing capability with energy storage, offer a potential pathway to lighter and more efficient aerospace systems.

This work investigates a carbon-fiber-based structural battery that utilizes carbon fiber as both a current-collecting, load-bearing electrode and a component of the composite structure. In contrast to lithium-ion chemistries, a zinc-based aqueous electrolyte is chosen for better environmental …