Mechanical Engineering Commons^™

Tradespace Exploration With Statistical Modeling Techniques And Immersive Visual Representation In Virtual Environments, Nikhil Raj

All Theses

Statistical modeling techniques combined with virtual reality (VR) visualization offer powerful new approaches to tradespace exploration in engineering design. The research presented addresses the challenge of analyzing and communicating insights from complex multidimensional datasets, particularly for autonomous ground vehicle systems.

Beginning with a review of statistical methods—including Principal Component Analysis (PCA), Analysis of Variance (ANOVA), and correlation analysis—the study examines their applications in tradespace exploration. Building on this foundation, three distinct visualization pathways connecting MATLAB data to virtual environments are developed and evaluated: VRML representation, STL conversion, and Blender integration. Each approach is assessed for its ability to maintain data …

Ultrafast Laser Surface Structuring For Wettability Control On Copper, Akshay Arvind Nagvenkar

All Theses

Wettability is a crucial surface property influencing various phenomena, including heat transfer, cell adhesion, and corrosion. Engineering devices can achieve superior performance by precisely manipulating surface wettability. As a result, extensive research has focused on developing surfaces that exhibit either extreme water attraction (superhydrophilic) or strong water repellency (superhydrophobic). Tailoring surface wettability paves the way for numerous applications, such as drag reduction in marine vessels, controlled drug delivery, efficient water collection, advanced liquid transport systems, oil-water separation, anti-corrosion coatings, friction reduction, and self-cleaning materials. Ultrafast laser surface structuring is a promising approach for engineering multifunctional surfaces, effectively modifying material properties …

Adjustable Dynamometer Motor Mount, Garrett Carson Ng, Elijah Siegel Reuven, Ethan Fong, Daniel Larimer

Mechanical Engineering

The Cal Poly Electrical Engineering Department and sponsor Dr. Dolan needs a manufacturable motor fixture that securely aligns motors of various sizes with dynamometers. Previous lab motor fixtures could not accommodate motors of different sizes, making precise alignment between motors and dynamometers time-consuming and unreliable. Our team developed a modular, manufacturable fixture capable of aligning various motor sizes quickly, accurately, and securely, enhancing lab consistency and usability.

Autonomous Defect Detection In Additive Manufacturing, John Samuel Poindexter Iv

Theses and Dissertations

Additive manufacturing (AM) is the process of creating a product by applying layers of material to build up to the final product. AM has revolutionized the field of manufacturing and has allowed more complex products to be manufactured at reasonable cost, quicker manufacturing time, and optimized material usage. Traditional forms of manufacturing were based on subtractive manufacturing, where by a product would be created by removing material from its source. AM is a new manufacturing process and faces significant challenges when it comes to manufacturing due to defects. Defects can vary from type and severity and can overall weaken or …

Baja Sae Brakes, Carson Moore, Jaedyn Michael Imhoff, Will Duncan, Matthew Shaffer

Mechanical Engineering

Historically, the Cal Poly Racing Baja SAE has produced a braking system that has proven unreliable and barely passes competition rules and inspections, leading to ill performing and unsafe brakes. The goal of this project is to produce a system and documentation that meets the requirements provided by Cal Poly Racing Baja SAE. The final design includes a transient braking model of the vehicle to set system requirements, universal custom front and rear calipers modified from “Cal Poly BSAE Custom Brake Caliper Senior Project”, and a revamped hydraulic harness. Leaning on the team’s previous work and modifying the custom calipers …

Carbon Fiber Cv Tripod Axle Design: Husker Motorsports Formula Sae, Taylor D. Boudreaux

Honors Program: Senior Projects (Public)

The 2024–2025 HMS Formula SAE senior design team successfully reduced axle system weight, cost, and improved manufacturability using a bonded tripod joint and ±45° intermediate modulus carbon fiber tube. The final design was validated on HMS 25, with no failures under rigorous testing.

Budget:
/="/"> Total project cost was $1,165.64, exceeding the initial $1,000 target due to unanticipated test rig expenses. However, per-axle production cost was reduced from $525.31 to $383.37 through in-house manufacturing, use of on-hand epoxy (DP460), and switching to cost-effective 7068 aluminum. The axle-specific cost was $766.74.

Timeline:
/="/"> Despite early delays from building a torsional testing …

Exploring Metal Additive Manufacturing In Martian Atmospheric Environments, Zane Mebruer

Mechanical Engineering Undergraduate Honors Theses

On-surface manufacturing is key to the success of a planetary colonization, especially that of Mars. However, traditional subtractive manufacturing processes are equipment, energy, and material intensive, meaning novel additive manufacturing (AM) processes must be pursued for this end. Selective laser melting, one of the most effective and versatile AM methods, would be incredibly beneficial to a Martian mission but requires an artificial argon atmosphere to create effective parts. The purpose of this study was to examine if carbon dioxide, the gas that makes up over 95% of Mars’ surface atmosphere, would be a sufficient substitute for argon in SLM fabrication. …

Thermal Characterization Of 3d Printing Materials For Increasing Insulation Potential And Practicality, Jackson H. Minnick

Mechanical Engineering Undergraduate Honors Theses

This study served as an exploration into the possible existence of a correlation between the infill lattice structure of a 3D printed wall section and the thermal performance of that sample as characterized by thermal conductivity measured in units of Watts per meter Kelvin. With the continual increase in the practicality, fidelity, and applicable fields of additive manufacturing, namely FDM 3D printing, research on specific print characteristics and their effects on the material and thermal characteristics of the part in question is steadily becoming more commonplace. Although the thermal conductivity of 3D printed wall sections as a function of infill …

The Prototype Of A Fully Automated Pressuremeter For Various Geotechnical Applications, Anuar Akchurin

Theses and Dissertations

The geotechnical engineering field requires high-quality in-situ testing equipment that ensures consistency in the test execution. This research focuses on developing and testing a prototype of a fully automated pressuremeter control unit to allow the industry to obtain reliable and controlled stress-strain data, thereby improving efficiency and reducing testing time.

The objectives of this work are to design and develop a system with the necessary components to perform the pressuremeter test, integrate the testing procedure into the state machine design, enable automated testing, and validate the results by comparing the stress-strain data with that obtained from the existing hand-operated pressuremeter …

Manipulating Martensitic Transformation And Residual Stress Development In Stress Superposed Incremental Forming Of Ss304, Elizabeth M. Mamros, Fabian Maaß, Thomas Gnaupel-Herold, A. Erman Tekkaya, Brad L. Kinsey, Jinjin Ha

Faculty Journal Articles

Stress superposition is one of the strategies used in metal deformation processes to increase the material formability, decrease the required forming forces, and create highly customized components. To investigate the effects of tensile and compressive stresses superposed to the single point incremental forming (SPIF) process, experiments and numerical simulations were conducted for a stainless steel 304 (SS304) truncated square pyramid geometry. Tensile stresses were superposed in-plane on the specimen blank by a custom hydraulic frame, and compressive stresses were incorporated via a polyurethane die. Identified parameters for a martensitic transformation kinetics model for SS304 were used in a two-step finite …

Co-Designing Manufacturing Systems For Robustness And Resilience: A Decision-Based Design Perspective, Mathew Baby

Theses and Dissertations

Manufacturing systems (MSs) comprise various stakeholders associated with the manufacture and supply of products required by customers and are interrelated by the flow of materials and information. The interrelated stakeholders make system-specific decisions and stakeholder-specific decisions across multiple levels of a decision hierarchy to satisfy many conflicting system-specific and stakeholder-specific requirements that define system and stakeholder performances. Given the stakeholder interrelations and conflicting nature of system-specific and stakeholder-specific requirements, system and stakeholder performances are correlated and conflicting.

In the Industry 5.0 era, there is an increased emphasis on the creation and equitable distribution of value among all the stakeholders in …

Advanced Porosity Control Of Cp780 Galvanized Steel During Gas Metal Arc Welding With Pulsed Arc, Carlos Adrián García Ochoa, Jorge Alejandro Verduzco Martínez, Francisco Fernando Curiel-López, Víctor Hugo López-Morelos, Jaime Taha-Tijerina, Ariosto Medina Flores, Maleni García Gómez

Informatics and Engineering Systems Faculty Publications

This study investigated the control of porosity during gas metal arc welding with pulsed arc (GMAW-P) of complex-phase 780 (CP780) galvanized steel. Due to the Zn coating on this type of steel, porosity forms during welding as a result of Zn vaporization. The objective was to optimize the welding parameters to minimize porosity with a design of experiments using an L9 orthogonal array to analyze the effects of peak current (Ip), pulse time (tp), and pulse frequency (f) in high-speed welding conditions. The results showed that porosity was significantly reduced with a peak current of 313 A, a frequency of …

Experimental And Theoretical Fracture Analysis Of Additively Manufactured Orthotropic V-Notches, Venkata Siva Sainath Bavapuram

Theses and Dissertations

This study presents a comprehensive investigation into the fracture behavior of additively manufactured orthotropic V-notched components made of Acrylonitrile Butadiene Styrene (ABS) material. The research integrates both theoretical and finite element approaches to evaluate stress intensity factors (SIFs) in Modes-I and II, which are fundamental in characterizing stress field distributions around notches under applied loading conditions. Unlike isotropic materials, where stress fields depend only on geometry of the component, the anisotropic nature of 3D-printed ABS introduces a dependency on material properties that necessitate different approaches to include anisotropy of the material.

Tensile specimens are 3D-printed with specific material orientations to …

Advanced Manufacturing Of Multifunctional Shape Memory Polymer Composites And Self-Healing Systems, John B. Konlan

LSU Doctoral Dissertations

The need for multifunctional light weight structures for engineering applications is on the rise. Multifunctional composites are desired because of their ability to combine multiple functionalities into one structure. The advantages of a high strength-to-weight ratio of multifunctional composites make them desirable and suitable for use in energy-efficient applications. Shape-memory polymers (SMPs) have attracted interest over the past several decades because of their multifunctional nature. They have found use in many applications such as aerospace, satellites, automobiles, textiles, and biomedical devices, where lightweight and multifunctionality are key. The self-healing nature of most SMPs makes them suitable for use in lightweight …

In-Situ Rtm Videos, Tanner Garrett

ScholarsArchive Data

This data set contains videos of resin infusion experiments.

Acoustic Filter For Biopharmacy, Nicholas Rivet

Three Minute Thesis (3MT)

The design and development of a novel flow induced acoustically tuned “filterless” filter is proposed. The proposed research is on developing two or more prototypes that function as a cell retention device for perfusion cell cultures used in continuous manufacturing of monoclonal antibodies and recombinant proteins. This research will provide a non-invasive, cost-effective, flexible, and robust cell retention device for sustainable manufacturing of biologics.

How Can The Adoption Of Biodegradable Packaging In The Beverage Industry Specifically Contribute To Reducing Single-Use Plastic Waste, And What Regulatory Or Cost-Related Challenges Hinder Its Widespread Implementation In Developing Countries?, Rebecca Aba Gaisie

2025 Awards for Excellence in Student Research and Creative Activity - Documents

This research investigates the potential of biodegradable packaging to reduce single-use plastic waste in the beverage industry and explores the regulatory and cost-related barriers to its adoption in developing countries. The beverage sector is a major contributor to global plastic pollution, and biodegradable alternatives offer a promising path toward sustainability. Using a mixed-methods approach, this study combines qualitative interviews with industry experts and case studies of businesses implementing biodegradable solutions, alongside quantitative survey data from 100 manufacturers and 200 consumers across Africa, Asia, and Latin America. Findings reveal that while biodegradable packaging significantly reduces plastic waste and appeals to environmentally …

Investigation Of Surface Quality And Productivity In Precision Hard Turning Of Aisi 4340 Steel Using Integrated Approach Of Ml-Moora-Pso, Adel T. Abbas, Neeraj Sharma, Khalid Alqusaibi, Mohamed Abbas, Rakesh Sharma, Ahmed Elkaseer

Mechanical Engineering

AISI 4340 steel has applications in gun barrels, where the surface quality of the barrel is the prime factor. This study explores the application of a machine learning (ML) approach to optimize the precision turning of an AISI 4340 steel alloy using both conventional and wiper tool nose inserts under varying cutting parameters, such as cutting speed, depth of cut, and feed rate. The analytical framework integrates experimental machining data with computational algorithms to predict key output parameters: surface roughness (Ra) and material removal rate (MRR). A Multi-Objective Optimization based on Ratio Analysis (MOORA) method is used for data normalization. …

40 - Design, Fabrication, And Installation Of Morphing Control Surfaces For Small-Scale Uas, Kyle Purser

Undergraduate Research Symposium

Morphing control surface technology, inspired by organic structures and compliant mechanisms, offers significant potential for enhancing the aerodynamic efficiency and performance of unmanned aerial systems (UAS). Despite these benefits, its adoption has been hindered by complexities in design, manufacturing, and installation, particularly when compared to traditional flap systems. This research explores the design, fabrication, and integration of morphing control surfaces for small-scale UAS using additive manufacturing techniques. To reduce costs and streamline the design process, fused deposition modeling (FDM) additive manufacturing was employed for component fabrication. An off-the-shelf Horizon Sport Cub S2 served as the testing platform, modified with a …

Fabrication Of Ultra High-Temperature Compact Heat Exchanger By Extrusion-Based Ceramic Additive Manufacturing, Abid Hasan Rafi, David W. Lipke, Jeremy Lee Watts, Greg Hilmas, Ming-Chuan Leu

Miners Solving for Tomorrow Research Conference

No abstract provided.

Image-Based Stage Prediction Of Pressure Injuries Using Deep Learning, Mehedi Tusar, Fateme Fayyazbakhsh, Ming-Chuan Leu

Miners Solving for Tomorrow Research Conference

No abstract provided.

Additive Manufacturing Of Thermoplastic Composites, Matik Heskin, K. Chandrashekhara, Richard Billo, Ming-Chuan Leu, Thomas P. Schuman

Miners Solving for Tomorrow Research Conference

No abstract provided.

Automated Tool Recognition And Retrieval, Tyler Rowden, Niloofar Zendedhel, Ming-Chuan Leu

Miners Solving for Tomorrow Research Conference

No abstract provided.

Impact Of Delayed Artificial Aging On Tensile Properties And Microstructural Evolution Of Directed Energy Deposited Scalmalloy®, Rachel Boillat-Newport, Sriram Praneeth Isanaka, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Scalmalloy® is a novel alloy designed to work with the unique processing inherent in additive manufacturing (AM). This alloy is post-processed using a single artificial aging treatment rather than a multistep heat treatment, as often noted in traditional manufacturing processes. Much of the literature details the impact of direct aging treatments around the temperature and time recommended by the manufacturer, 325 °C for 4 h; however, few studies have explored the impact of delayed artificial aging on the resulting mechanical and microstructural behavior. This study explored this missing link and determined the impact that the time between the fabrication of …

Theoretical Analysis Of The Fiber Flow Movement Under The Influence Of Columns, Avazbek Azamatovich Obidov, Rashid Gulomjonovich Rakhimov

Technical science and innovation

During the study, the optimal design for testing the improved fiber cleaning device was initially selected, and a process flow diagram of the fiber cleaning chamber was created for theoretical studies. According to this process flow diagram, based on theoretical studies, the behavior of fibers in the grate of the fiber cleaning device was studied, and the effect of changing the geometric parameters of the grates on the cleaning efficiency was determined. Using the developed mathematical model, graphs were constructed for the dependence of the fiber flow rate on the angle of coverage at different values of the angular speeds …

A Gaze-Driven Manufacturing Assembly Assistant System With Integrated Step Recognition, Repetition Analysis, And Real-Time Feedback, Haodong Chen, Niloofar Zendehdel, Ming C. Leu, Zhaozheng Yin

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Modern manufacturing faces significant challenges, including efficiency bottlenecks and high error rates in manual assembly operations. To address these challenges, we implement artificial intelligence (AI) and propose a gaze-driven assembly assistant system that leverages artificial intelligence for human-centered smart manufacturing. Our system processes video inputs of assembly activities using a Convolutional Neural Network (CNN) and Long Short-Term Memory (LSTM) network for assembly step recognition, a Transformer network for repetitive action counting, and a gaze tracker for eye gaze estimation. The application of AI integrates the outputs of these tasks to deliver real-time visual assistance through a software interface that displays …

Intelligent Turning Cyber-Physical Systems Modeling Using Sysml, Prithbey Raj Dey, David Lee Enke, Mario F. Buchely

Engineering Management and Systems Engineering Faculty Research & Creative Works

Cyber-Physical Systems (CPS) support industrial automation that incorporates people, hardware, signal, computation, and control using networking to achieve desired results. The complex automated CPS design demands a standard and comprehensive approach to appropriately identify the system requirements, define the architecture, and model the relationships among the software and hardware components. Systems Modeling Language (SysML) provides the capability for a comprehensive modeling to capture the desired design requirements in the systems architecture. SysML enables performance estimation of the model by analyzing constraints while identifying interactions among the components through various behavioral diagrams. In this paper, SysML is applied to the design …

Experiment-Based Superposition Thermal Modeling Of Laser Powder Bed Fusion, Cody S. Lough, Tao Liu, Robert G. Landers, Douglas A. Bristow, James A. Drallmeier, Ben Brown, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Parts experience significant local thermal variations during the Laser Powder Bed Fusion (LPBF) metal Additive Manufacturing (AM) process, providing a potential source of defects. Near real-time thermal predictions can enable better process planning and facilitate corrections on subsequent layers to enable the engineering of laser parameter and scan path combinations that avoid defect inducing scenarios. This paper considers an experiment-based Discrete Green's Function (DGF) thermal model for temperature field prediction in LPBF. An analytical framework is developed and used to calculate an experimental DGF (i.e., powder bed's single pulse temperature response) from spatiotemporal Short-Wave Infrared (SWIR) camera data. The extracted …

Improvement Of Microcracking And Mechanical Properties Of Tungsten Fabricated Via Laser Powder Bed Fusion Through Alloying With Reactive Secondary Constituents, William S. Mockel

Theses and Dissertations

Tungsten (W), a Group VI transition metal, possesses a number of advantageous properties, most notably its impressive mechanical performance at extreme temperatures. While tungsten's nature render traditional manufacturing methods difficult, additive manufacturing through laser powder bed fusion (LPBF) presents a promising avenue for fabricating tungsten components. However, the material’s high ductile-to-brittle transition temperature combined with the embrittling effect of impurities mean that the residual stresses imparted by LPBF result in microcracking in tungsten, degrading its usefulness. This study sought to improve the characteristics of LPBF-W through the removal of embrittling oxygen content via alloying with low concentrations of reactive elements, …

Development Of Planetary Drive System For Formula Sae Electric Race Car, Brian Wong, Bradley Maruoka, Joshua Charles Fine, Madison Kai

Mechanical Engineering

Hub motors are compact electric motors mounted directly on each outboard wheel hub. Utilized in Formula SAE and Formula Student vehicles, this configuration offers several advantages over traditional drivetrains, including packaging optimization within the chassis, vehicle traction, and improved efficiency. Although hub motors are not yet common in 4WD vehicles, they are being explored for use in EVs and may become more common in the future. Every year, Cal Poly Racing FSAE designs and builds a formula-style race car. To improve drivetrain performance, the team is investigating the achievability of a hub motor 4WD drivetrain, requiring extensive research, development, and …