Mechanical Engineering Commons^™

Human Comfort Modeling, Measurement, And Improvement In Human–Robot Collaboration, Yuchen Yan

All Dissertations

A dissertation is proposed to explore human comfort in human-robot collaboration (HRC) through modeling, prediction, and enhancement methodologies. Human comfort is a crucial yet underexplored factor in HRC, directly influencing task efficiency, trust, and overall collaboration effectiveness. Understanding the influential factors, developing computational models, and refining methods to improve human comfort in HRC are essential steps toward advancing the field of collaborative robotics. To address these challenges, multiple studies have been conducted. A series of experimental studies were performed to investigate how robot motion-based parameters affect human comfort in HRC. These studies examined both analytical comfort modeling approaches and physiological …

Material Extrusion 3d Printing Of Metal Alloy: Material, Methods And Application., Sihan Zhang

Electronic Theses and Dissertations

Material extrusion (MEX) additive manufacturing presents a promising pathway for producing metal components with complex geometries while avoiding the safety hazards associated with loose powder handling in conventional metal additive manufacturing processes. This dissertation investigates the development and optimization of MEX processes for aluminum alloys, addressing critical challenges in feedstock formulation, printing parameter optimization, and post-processing strategies. Three distinct approaches were explored to advance the capabilities of aluminum MEX: filament-based processing of 6061 aluminum, paste-based extrusion of 6061 aluminum, and development of a novel aluminum-magnesium-tin alloy system for space manufacturing applications. The filament-based approach successfully demonstrated the production of 6061 …

Microstructural Investigation Of Graphene Reinforced Nickel Aluminum Bronze Prepared Via Laser Powder Bed Fusion, Wen Qian, Maxwyll Mcconnell, Jazmin Ley, Luke Schwaninger, Xin Chen, Bai Cui, Joseph A. Turner

Mechanical Engineering Faculty Publications

Nickel aluminum bronze (NAB) powders coated with reduced graphene oxide (RGO) were successfully fabricated using additive manufacturing (AM) via laser powder bed fusion. The resulting samples were characterized using a suite of complementary techniques, including x-ray diffraction, scanning electron microscopy, energy-dispersive x-ray spectroscopy, nanoindentation, x-ray computed tomography, and electron backscatter diffraction. These methods were employed to reveal the micro- and nanoscale features within the fine dendritic microstructure. The as-fabricated microstructures were observed to deviate significantly from typical as-cast configurations. In the AM RGO-coated NAB specimens, the formation of the κ_I phase was notably suppressed and is attributed to the …

Predicting Leakage From Nuclear Material Containers At Los Alamos National Laboratory Through Drop Testing, Leak Testing, Finite Element Analysis And Digital Image Correlation, Jude M. Oka, Yu-Lin Shen, Osman Anderoglu, Pankaj Kumar, Rajendra Vaidya

Mechanical Engineering ETDs

Los Alamos National Laboratory (LANL) relies on containment vessels to safely manage special nuclear material. These containers are subject to rigorous testing—such as drop, fire, and water ingress testing—to ensure integrity under adverse conditions. While elastomer-based seals are well studied, metal-to-metal sealing mechanisms remain under investigation, particularly under dynamic loading. This research focuses on the relationship between container mating surfaces and impact loading through drop testing. Finite Element Analysis (FEA) models were developed and validated using Digital Image Correlation (DIC) to measure strain during impact. Drop tests at varying heights showed strong correlation between FEA and DIC results, confirming the …

Research On Technology Opportunity Identification By Integrating Technology Attribute Analysis And Competitive Environment Scanning —— A Case Study Of Industrial Robots, Daobin Gao

Journal of Scientific Information Research

[Purpose/significance] Placing technology opportunity identification in the perspective of technology attribute analysis and competitive environment scanning provides intelligence support for enterprises to select technology opportunities and formulate technology competitive strategies in complex and changing market competition environments.

[Method/process] Using patents as the data source, first, the BERTopic model is used to explore potential technical topics, Secondly, starting from the technical attributes, and from both global and local perspectives, we propose indicators of technical importance and technical attention, and use their cross screening to select candidate sets of technical opportunities, Finally, a market competition intensity index that takes into account market …

Aerospace Fastener Installation Tool, Anthony I. Berghout, Matthew K. Eggers, Liam Dunsmore, Jose Pardo

Mechanical Engineering

Contamination, particularly in aerospace manufacturing environments, is a significant concern, especially with fastener designs that incorporate torque-rated breakaway pieces for easier installation. These breakaway pieces are also known as pintails. Howmet has tooling that can collect loose pintails during installation, but they have small capacities and are not ergonomic for aerospace technicians. Their current need is for a light and ergonomic tool capable of installing a wide variety of Ergo-Tech® fasteners while having a large capacity to collect pintails and improve aerospace manufacturing methods. For this Critical Design Stage, we have finalized a design that allows Pintails to pass through …

Aluminum Boat Rotation Fixture, Kevin W. Heiskell, Nathaniel M. Conway, James S. Knowles, Austin J. Kehl

Mechanical Engineering

Aluminum fishing boats are widely used for various water-based activities, including fishing, transportation, and recreation. Their lightweight construction makes them ideal for maneuverability, particularly in regions like Australia. However, the manufacturing process presents challenges, specifically the need to weld both the interior and exterior seams of the hull. As the boat’s weight increases during assembly, flipping it becomes difficult and potentially hazardous. Traditional methods such as cranes or forklifts are inefficient and pose safety risks. To address this, our team developed a rotating fixture that secures the boat at two connection points, one at the bow and one at the …

In-Situ Defect Detection In Selective Laser Melting Using Convolutional Neural Networks, Ethan Gaigalas

Master's Theses

This thesis develops and trains a convolutional neural network (CNN) to classify defects in metal parts produced by selective laser melting (SLM) using acoustic emission (AE) data. The model successfully identified porosity and standard build layers with high accuracy but consistently struggled to classify lack of fusion (LOF) defects, regardless of input type, normalization, or class count. These results suggest that while AE signals contain distinguishable features for certain defect types, LOF signals may be too subtle or inconsistent for reliable detection. The study addresses the ongoing challenge of in-situ quality monitoring in metal additive manufacturing, where defects like cracks, …

7lr-C Upper Limb Dancing Prosthetic, Victor Ochoa, Zoe Kelemen, Ged Mulingtapang, Marley Paltiel

Mechanical Engineering

Ella Wallis, a student at Cal Poly and performer in the Cal Poly Drag Club with a trans humeral upper limb difference, wants a prosthetic device that allows for a large range of motion and high degree of articulation to help them better dance in the style of voguing, allowing them to express themselves further while performing. The prosthetic arm is body-driven and relies on momentum to reposition. It attaches to the user through a harness, which is clipped to a socket with elastic straps to not impede the shoulder’s range of motion. The design contains urethane resin, aluminum, stainless …

Llnl Raft Flash Pole Redesign, Jack Stangel, Evan Wolfson, Jake Borden, Alexander Meeter

Mechanical Engineering

During research exercises in the ocean, Lawrence Livermore deploys a fleet of rafts outfitted with flash modules affixed to tall poles (in tandem called flash poles) that flash while a photo is taken to act as datums for data collection. The current flash pole design that the LIDSS (Lawrence Livermore Independent Diagnostic Scoring System) team uses is too short to be visible in high seas, not mechanically suited to be made taller, too susceptible to the elements and blunt impact and too difficult to service. We aim to solve these issues.

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 …

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 …

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 …

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 …

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 …

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 …

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 …