Mechanical Engineering Commons^™

Cvj Torque Loss Dynamometer, Malaika Sriram, Coleman Brown, Zachary Norris, Logan Mast, Chris Mattis

Mechanical Engineering

This report details the design and results of a dynamometer testing rig built to measure torque losses in constant velocity joints (CVJs) for Cal Poly Racing's Baja SAE team. The rig spins a flywheel connected to articulable CVJs up to 800 RPM using a motor, then decouples it and measures the spin-down rate from 800 to 100 RPM to calculate angular acceleration and torque loss. The data collected from this dyno will be used to inform freewheel packaging for future Baja car development.

Three-Dimensional Numerical Investigation Of Darrieus-Type Vertical-Axis Wind Turbine With Active Suction Cavity, Ahmed Elbaz, Nabil Mahmoud Dr, Mohamwd Akmal Ammar Dr

Mechanical Engineering

The current work aims at improving the power conversion efficiency of a widely used type of wind turbine, the vertical-axis wind turbine (VAWT). This is achieved by actively controlling the boundary layer characteristics on turbine blades through wall suction. The effect of this active control technique on the performance of a NACA0018 Darrieus vertical-axis wind turbine is investigated by means of three-dimensional numerical simulations using ANSYS-FLUENT software. Pressure-based incompressible Unsteady Reynolds-Averaged NavierStokes (URANS) equations, complemented with the Shear Stress Transport (SST) k-ω model for turbulence closure, were solved. A detailed computational methodology is adopted, including domain extent, mesh refinement, and …

Multi-Cater Pack Heat Sealer, Ivan Medina-Zepeda, Laurent Hirakata, Donovan Furtado, Cody Ngan

Mechanical Engineering

The Multi-Cater Pack Heat Sealer was developed to support Achievement House, a non-profit organization that employs adults with intellectual and physical disabilities and is facing increasing demand for sealed cater packs. Existing single-pack sealers limited both throughput and accessibility, which led to the creation of a 3D printed attachment for a 40-inch impulse heat sealer. The attachment allows nine packs to be sealed at the same time and includes a tray-style trapdoor that allows for quick unloading. The need for accessibility and usability guided the design throughout the process. Alignment guides improve placement consistency, and the ergonomic layout accommodates both …

Water Bottle Lid Co Detector, Zeke Bukovansky, Jake Siegel, Jack Wisegarver, Cody Rudman

Mechanical Engineering

This project introduces a portable carbon monoxide detector integrated into a water bottle lid to give users a simple way to stay aware of CO exposure in daily life. The design packages an electrochemical sensor, onboard electronics, and clear visual and audible alerts into a compact form that fits standard bottles. By embedding sensing into an object people already carry, the device offers a practical path toward reducing unrecognized CO risks and improving personal safety.

Exploratory Diver Geotechnical Equipment (Edge), Angel Villicana, Merrick Zellers, Erik Heuchert, Lucas Heuchert

Mechanical Engineering

The goal of this report is to showcase how our final Core Sampler design and prototype address the needs of Navy Divers. Geotechnical equipment for Navy divers has not been updated since the early to mid-1980s, resulting in imprecise and outdated sampling methods. The primary purpose of this project is to enhance, modernize, and redesign a tool to collect a minimally disturbed core sample of the seabed for geotechnical evaluation. This report presents the full development of our project from concept to verification and final outcomes. It begins with the statement of disclaimer, followed by a four-panel executive summary and …

Cal Poly (Cp) Legged Robot, Sebastian Barboza, Jonathan Mchale, Isabella Sorensen, Isaac Golan

Mechanical Engineering

The Navy spends $60 billion annually on dangerous ship maintenance performed by sailors. To save lives and resources, the Naval Surface Warfare Center (NSWC) is looking for robots to replace sailors and navigate ships to perform various tasks. Robots with tracks and wheels have been most recently explored by NSWC, however they have encountered significant problems navigating the ships, especially through naval ship doorways with a significant ledge. By using a legged robot, our team hopes to solve these problems and have a robot that can navigate the ship with relative ease and stability.

Thermal Performance Variations Of Office Spaces In Educational Buildings Resulting From Façade Orientation: An Egyptian Case Stud, Hesham Safwat, Ahmad Elshamy, Rania Rushdy Moussa, Iman El-Mahallawi El-Mahallawi, Engy Elshazly, Mahmoud Mahmoudalghrieb

Mechanical Engineering

This paper investigates the thermal performance of an office floor within the Faculty of Engineering at the British University in Egypt (BUE), located in Cairo, a city characterized by a hot arid climate. The study focuses on understanding the building’s thermal behavior by comparing two identical office rooms: Room 212 (north-facing) and Room 201 (south facing). Utilizing dynamic thermal simulations with TRNSYS 18 for a full year, the research specifically analyzes the impact of these opposite orientations on indoor space temperature, total cooling loads, the monthly heat absorbed by various building surfaces, and the heat absorbed per unit area for …

Impact Of Composite Materials Research On Underrepresented Communities, Neil Mahesh Bedagkar, Ramanan Sritharan, Wyatt Barnes

Mechanical Engineering

This research assesses how advancements in composites material research affect communities from lower socioeconomic backgrounds, using a dual track strategy to quantitatively and qualitatively examine their impact. A keyword-based classification algorithm was applied to a sample of research papers from ScienceDirect spanning the last 24 years to quantify which engineering industries benefit most from this research. The findings indicate that the construction industry benefits the most, followed by the automotive, defense, renewable energy, and biomedical sectors. A broader qualitative analysis of the social implications of these industries was also conducted to provide context. Each sector were found to have either …

Synergistic Enhancement Of Tribological Behavior And Colloidal Stability In Cuo Nanolubricants Via Ligand Tuning, Sherif Elsoudy, Sayed Akl Akl Dr, Sayed Akl A. Akl Dr, Esm Lane, Abas Hadawey, Philip D. Howes

Mechanical Engineering

Nanoparticle-based lubricants, or nanolubricants, can exhibit superior tribological properties compared to unmodified base oils. However, these performance gains are highly dependent on the nanoparticle surface chemistry, particularly in maintaining stable colloidal dispersions. This study explores the influence of oleic acid (OA) and oleylamine (OAm) functionalization on the tribological and colloidal properties of CuO nanoparticles dispersed in an SAE 20W50 base oil. We present a hybrid optimization framework combining Response Surface Methodology (RSM) with Bayesian Optimization (BO) to identify the optimal OA to OAm ratio (OA–OAm) for CuO nanolubricants. Unlike prior studies that employed either RSM alone or trial-and-error approaches, this …

Solar Absorption Cooling Systems – A Case Study In Egypt, Hesham Safwat, Iman El-Mahallawi

Mechanical Engineering

Climate change with Egypt’s increasingly hot weather and plans towards energy transition, addressing an approach for clean HVAC (Heating, Ventilation, and Air Condition) solutions is becoming requisite. This paper examines the potential of utilizing solar absorption cooling systems in institutional buildings by presenting a case study of a proposed solar absorption cooling system for a library building with an area of 4402 m2, located at the British University in Egypt. The proposed solution is to replace 30% of the existing conventional air conditioning units with a hot-water driven single-effect absorption chiller powered by solar thermal vacuum tube solar collectors, coupled …

Efficient Thermal Design Of Data Centers, Keats M. Baggett, Andrew Ergood, Colin Brace, Jack Zilligen

Mechanical Engineering

Our sponsor needs a way to categorize and quantify the top 3 colocation center sites based on a series of criteria for given power specs. The sponsor also needs a single innovative cooling method to meet thermal and power requirements while also being manufacturable at scale. This device must also be able to interact with the given Colocation Heating Ventilation and Air Conditioning (HVAC) system. This design will be tested to provide insight and data that will be applicable to further the development of colocation center cooling. This project will be executed by the Cal Poly senior project team and …

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 …

2-Axis Solar Panel Tracker, Danica Wong, Oliver Barnaal, Anton Orme

Mechanical Engineering

Solar panels generate energy from sunlight. To do this it’s important that they remain pointed at the sun throughout the day. The Cal Poly Micro Grid Lab runs a class that uses a student made solar panel and tracking mount as an instructional tool. This project is beginning to show signs of wear from outdoor use and is unable to run without constant input due to some significant design flaws. The lab needs a new version of the mount to be made that is significantly more reliable and easier to use.

Edwards Lifesciences: Esheath+ Scoring Automation, Tony Lee Avina, Kirth Hirth, Charith Sunku, Humberto Salazar-Banuelos

Mechanical Engineering

Due to a non-disclosure agreement with our sponsor, Edwards Lifesciences, the contents of the report have been omitted.

Kinetic, Wind-Driven Metal Sculpture, Irene Songhee Han, Aiden Brown Largay, Madeline Vang Xiong

Mechanical Engineering

The Interdisciplinary Senior Design Team “Flying Flora” from Cal Poly’s College of Engineering has been tasked with designing and building a wind-driven dynamic metal sculpture for the San Luis Obispo Botanical Garden. The botanical garden wants to fill a large, centrally located vacant space with a kinetic sculpture to attract and welcome visitors. The final design, as approved by the garden’s directors, features a large metal California poppy below a stained-glass and metal butterfly. The flower rotates smoothly in typical wind conditions, drawing the attention of visitors to the sculpture. The butterfly is stationary, positioned at an angle from the …

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 …

Cryogenic Fuel Delivery System, Carter Josef, Reilly Humphreys, Joseph O'Connor, Nick Spreen

Mechanical Engineering

This project presents the design and validation of a cryogenic fuel delivery system aimed at enabling sustainable aviation through hydrogen fuel vaporization. Developed by a team of senior mechanical engineering students at Cal Poly and sponsored by Boeing, the system utilizes atmospheric air to vaporize liquid nitrogen, used as a stand-in for hydrogen, via forced convection heat exchangers, eliminating the need for engine-supplied heat and reducing parasitic loads. A feedback loop and turbine component are integrated to regulate pressure and recover energy, respectively. A benchtop prototype was built and tested to evaluate system performance, with results closely aligning with analytical …

Conversational Social Robot, Julianna M. Christopoulos, Mackenzie Goldman, Cece E. Hujanen, Jared Hunter

Mechanical Engineering

Background: Social robots are used in various settings to reduce burden on human workers and expand opportunities for people in need of assistance.

Challenge: Design a humanoid robot head and torso capable of holding conversations and interacting with a user using a LLM and motion. Conversations are limited to discussing Cal Poly resources and opportunities with visitors to the Bently Research Center on campus.

Scitechatorium, Olivia Lafferty, Yvonne Brien Miller, Colton Swinth, Savannah Pinheiro, Gage Heinze

Mechanical Engineering

Bellevue Santa-Fe Charter School (Bellevue) is a K6th grade public charter elementary school in Avila Beach, California. The primary focus at Bellevue is fostering unique learning experiences, empowering students through project-based learning, and engaging students in creative endeavors. Following these themes, the school has allocated space and funding for an on-campus science and technology museum known as the SciTechatorium. The museum is currently open during students’ lunch period, providing interactive displays on concepts in human biology, nature and wildlife, physics, and electronics. Bellevue’s K-6th grade science teacher, Christian Strauli, and Bellevue parent volunteers are primarily responsible for the museum’s upkeep …

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 …

License To Drill, Gabrielle Noemi Orlando, Alexcias Olga Meeks, Dayana Guadalupe Gonzalez, Mark Dahmen

Mechanical Engineering

The goal of this project is to provide the student machine shops with an updated License to Drill (LTD) certification training, formally known as the Red Tag. The current training has two key components: a preliminary Canvas course and an in-person training with a safety tour, safety quiz, and a hands-on project. Currently, the hands-on project is outdated and unengaging. Thus, the primary focus is to replace it with an inspiring and memorable project, which includes written and visual instructional content on how to make it. The Canvas will thus be updated, a new instructional video will be created, and …

Pendulum Wave Generator, Abigail Jocelyn Romero, Paul Staley, Wendy Dong, Kyle Schumacher

Mechanical Engineering

The Cal Poly Mechanical Vibrations Laboratory (Vibes Lab) serves to educate and excite students about mechanical vibrations through hands-on experiments. While the lab contains several relatively complicated technical experiments, it lacks simple demonstrations with immediate visual interest to appeal to audiences with less technical backgrounds. Because of this, faculty desired a fun and interactive demonstration project that could be operated with no prior training. The project chosen for this is a Pendulum Wave Generator which is a set of multiple pendulums with differing lengths that combine to create complex and observable patterns over time. This project was completed by a …

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 …

Foot Pedal Assistive Device, Julian Rubinstein, Connor Jessen, Isabelle Utsler, Sydney Alexander

Mechanical Engineering

Individuals with lower-limb mobility problems may have trouble accurately locating the pedals of a three-pedal manual transmission car, and some medical conditions cause individuals to fatigue more quickly when driving. This project aimed to create a device that assists in locating the user’s feet, indicates to the user which pedals are currently in use, and provides a visual and physical warning if they are not in the correct place. The project sponsor, Alan Keizer, is the primary stakeholder in this project. This device will be designed specifically for Alan’s Subaru BRZ and will address Alan’s specific lower-limb mobility issues that …

Van Accessibility, Ann Larson, Camelia Anne Noureddine, Stephanie Rose Ruzicka, Kayla Joanne Gowey

Mechanical Engineering

The SLO Achievement House provides resources and activities for their clients, including daily trips to different parts of the community, to keep their clients connected to society. These trips require the clients, many of whom struggle with general mobility and strength, to step up to the high entrance of a van or company car. This daily activity poses a challenge both physically and emotionally for the clients. The current solution utilizes commercially available step stools, which lack handrails, overall stability, and adequate step depth. The Achievement House needs a stool or ramp tailored to their client’s needs and their specific …

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 …

Drone Package Delivery System, Aiden Tyler Sim, Ryan Anders O'Toole, Matthew Karl Wyant, James Shaw Glanville

Mechanical Engineering

In response to the demands of the 2025 C-UASC (California Unmanned Aerial Systems Competition), our team developed an autonomous drone payload delivery system capable of two distinct delivery modes: a precision-controlled descent and a high-speed aerial drop. Designed for modular integration with UAV platforms, the system prioritizes reliability, accuracy, and simplicity under desert environmental conditions. Our solution features a custom winch mechanism with a programmable stepper motor, a passive mechanical hook for tension-based release, and a servo-actuated trapdoor for high-altitude drops. The design was extensively tested for structural integrity, motor torque requirements, drop precision, and electronics reliability—culminating in a robust …