Mechanical Engineering Commons^™

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 …

Further Development Of A Low-Energy Arc-Ignition System For Nytrox/Abs Hybrid Propulsion Systems, Stephen A. Whitmore, Jared S. Coen, Ryan J. Thibaudeau

Mechanical and Aerospace Engineering Faculty Publications

Utah State University has developed a high-performance “green” hybrid propulsion technology based on the unique electrical breakdown properties of 3D-printed acrylonitrile butadiene styrene. Using 3D-printed ABS as fuel, typical startup sequences require approximately 5–15 joules and, once started, the system can be sequentially fired with no additional energy inputs required. The number of possible ignitions is limited only by the amount of fuel. The most technologically mature version uses gaseous oxygen (GOX) as oxidizer and 3D-printed ABS as fuel. While GOX is mass-efficient, it lacks volumetric efficiency unless highly pressurized. Nytrox, a blend of GOX and nitrous oxide, improves propellant …

Construction Of A Deffi Sprayer: Using 3d Printer Methodology And Techniques For Cost-Effective Analysis Using Desi Mass Spectrometry Imaging, Ryan Karst, Savvy Stevens, Luke Amos, Logan Koester, Ethan Newbold, Karson Whitaker

Symposium Projects

Using 3D Printer Methodology and Techniques for Cost-Effective Analysis using DESI Mass Spectrometry Imaging

Atomized Oxidative Polymerization As A 3d Printing Platform For Binder-Free, Bulk Conductive Polymer Architectures, Tazdik Patwary Plateau, Hiep Pham, Jonghyun Park

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Translating the ultrahigh intrinsic conductivity of conjugated polymers into bulk 3D architectures remains a formidable challenge due to the fundamental dichotomy between rheological printability and electronic purity. Existing strategies necessitate a compromise: solution-processing requires insulating binders that degrade charge transport, while binder-free vapor-phase polymerization (VPP) is kinetically confined to surface-limited thin films by diffusion constraints. Here, we introduce atomized oxidative polymerization (AOP), a manufacturing paradigm that overcomes these kinetic barriers via active, layer-by-layer monomer atomization. This approach ensures stoichiometric reaction conditions throughout the printed volume, driving a structural transition toward highly conductive quinoid-dominant chains with enhanced π-π stacking. The resulting …

Three-Dimensional Printing Of Calcium Phosphate-Mesoporous Bioactive Glass Scaffolds For Bone Tissue Engineering, Ana Beatriz Gomes De Carvalho, Lais Medeiros Cardoso, Igor Paulino Mendes Soares, Joyce Rodrigues De Souza, Arpita Roy, Prabaha Sikder, Et. Al.

Mechanical Engineering Faculty Publications

Calcium phosphate cements (CPCs) and biomaterials, such as mesoporous bioactive glass (MBG), are critical for bone tissue engineering. This study aimed to 3D-print CPC scaffolds modified with MBG to enhance their osteogenic potential and regenerative ability. MBG powder was synthesized and characterized using transmission electron microscopy (TEM), X-ray diffraction (XRD), and nitrogen adsorption-desorption techniques. A commercial CPC ink (hydroxyapatite/alpha-tricalcium phosphate) was mixed with 5% MBG (w/w; CPC/MBG), and, after rheological assessment, the mixture was used to obtain scaffolds via 3D printing. These scaffolds were then tested for chemical, morphological, and mechanical properties, as well as ion release analysis. Unmodified CPC …

Experimental And Numerical Study On The Influence Of Carbon Fiber Reinforcement On The In-Plane Compressive Properties Of 3d Printed Hexagonal Honeycomb Core Structures, Deon Wallace

All Theses

There is difficulty with numerically replicating the behavior of composite honeycomb core structures numerically due to the trouble of gathering material properties from a hollow structure. Also, complex part geometries and carbon fiber reinforcement strategies can lead to unwanted structural weaknesses and variance in material properties that may not be reflected in numerical analysis when the part is additively manufactured. In this study, edgewise compressive testing is used to characterize the mechanical behavior and performance characteristics of these structures. The experimental results indicate an increase in the Young’s moduli of the honeycomb core structures as carbon fiber concentration increases. However, …

Experimental Investigation Of 3d Printed Tpu Triboelectric Composites For Biomechanical Energy Conversion In Knee Implants, Osama Abdalla, Milad Azami, Amir Ameli, Emre Salman, Milutin Stanacevic, Ryan Willing, Shahrzad Towfighian

Mechanical Engineering Faculty Scholarship

Although total knee replacements have an insignificant impact on patients’ mobility and quality of life, real-time performance monitoring remains a challenge. Monitoring the load over time can improve surgery outcomes and early detection of mechanical imbalances. Triboelectric nanogenerators (TENGs) present a promising approach as a self-powered sensor for load monitoring in TKR. A TENG was fabricated with dielectric layers consisting of Kapton tape and 3D-printed thermoplastic polyurethane (TPU) matrix incorporating CNT and BTO fillers, separated by an air gap and sandwiched between two copper electrodes. The sensor performance was optimized by varying the concentrations of BTO and CNT to study …

Impact Of Print Speed And Nozzle Temperature On Tensile Strength Of 3d Printed Abs For Permanent Magnet Turbine Systems, Wirawan Wirawan, Hilmi Iman Firmansyah, Satworo Adiwidodo, Mohammad Sukri Mustapa

Journal of Mechanical Engineering Science and Technology (JMEST)

Operational parameters must be integrated into turbine systems' main components, which are determined by turbine systems' functional requirements. The need for producing component designs more effectively raises the possibility of using additive manufacturing. The study focuses on the optimization of the mechanical properties of the principal components of magnetic turbines manufactured with 3D printers using Acrylonitrile Butadiene Styrene (ABS), by changing the temperature and speed of the nozzle. The approach consisted of modeling a standard test piece in CAD software and producing ABS-based test pieces using a 3D printer with print speeds of 50, 70, 90, and 110 mm/s and …

3d Printed Cnt/Tpu Triboelectric Nanogenerator For Load Monitoring Of Total Knee Replacement, Osama Abdalla, Mahmood Chahari, Milad Azami, Amir Ameli, Emre Salman, Milutin Stanacevic, Ryan Willing, Shahrzad Towfighian

Mechanical Engineering Faculty Scholarship

This study presents the development and characterization of a novel triboelectric nanogenerator (TENG) designed as a self-powered sensor for load monitoring in total knee replacement (TKR) implants. The triboelectric layers comprise a 3D-printed thermoplastic polyurethane (TPU) matrix with carbon nanotube (CNT) nanoparticles and kapton tape, sandwiched between two copper electrodes. To optimize sensor performance, the proposed CNT/TPU TENG sensor is fabricated with varying CNT concentrations and thicknesses, enabling a comprehensive analysis of how material composition and structural parameters influence energy harvesting efficiency. The 1% CNT/TPU composite demonstrates the highest power output among the tested samples. The solid CNT/TPU-based TENG generated …

Predicting Strut Geometry Of Pcl And Dmso2 Biocomposites From Nozzle To Deposition In Bio-Scaffold 3d Printing, Jae-Won Jang, Kyung-Eun Min, Jun-Hee Park, Cheolhee Kim, Sung Yi

Mechanical and Materials Engineering Faculty Publications and Presentations

The field of tissue engineering increasingly demands accurate predictive models to optimize the 3D printing process of bio-scaffolds. This study presents a unified numerical model that predicts extrusion velocity and strut diameter based on printing conditions and the material properties of polycaprolactone (PCL) and dimethyl sulfone (DMSO2) composites. The extrusion velocity was simulated using Navier–Stokes equations, while the strut diameter was calculated via a surface energy model. For PCL, the extrusion velocity showed a temperature coefficient of 23.3%/°C and a pressure coefficient of 19.1% per 100 kPa; the strut diameter exhibited a temperature coefficient of 21.6%/°C and a pressure coefficient …

Nasa Design And Analysis Of Pegda Hydrogels For Microgreen Cultivation In Space, Fabiha Samiha, Luis E. Luna, Kelly Wu, Gabriel Antigua, Artur Abramyan

Publications and Research

Through multiple experiments, Polyethylene Glycol Diacrylate (PEGDA), a biocompatible polymer, has shown potential as a soilless growing medium for microgreens like arugula. However, a challenge arises when the roots run out of space within the hydrogel capsule, pushing the plant out of position and preventing it from absorbing nutrients from the PEGDA.

This study aims to address this challenge by analyzing different 3D-printed mold designs for the creation of the hydrogel capsules. The most promising designs include coil and tree-branch models, which encourage roots to grow in a way that relieves pressure on the leaf side of the plant, helping …

Effects Of High Temperature Compaction On 3d Printed Carbon Fiber Reinforced Polymer Composites, John D. Barber

Mechanical & Aerospace Engineering Theses & Dissertations

The aim of this dissertation was to study the effects of hot temperature compaction (HTC) upon the polymorphism and the mechanical behavior of an additively manufactured (AM), carbon fiber reinforced polyamide (PA6). Different pressure and temperature levels during HTC were tested to determine the overall effect upon the mechanical behavior and the material crystalline composition. Treated, carbon fiber reinforced PA6 samples were analyzed using differential scanning calorimetry, x-ray diffraction, thermogravimetric analysis, scanning electron microscopy, double cantilever beam testing and three-point bending testing. When considered with respect to as-printed samples, an HTC temperature of 190°C combined with 80 psi pressure resulted …

Polymorphism And Mechanical Behavior In Hot-Pressed 3d-Printed Polyamide Composite: Effects Of Pressure And Temperature, John Barber, Patricia Revolinsky, Jimesh Bhagatji, Diego Pedrazzoli, Sergii Kravchenko, Oleksandr Kravchenko

Mechanical & Aerospace Engineering Faculty Publications

The aim of this work is to study the effect of high-temperature compaction (HTC) upon the polymorphism and the mechanical behavior of an additively manufactured (AM) carbon fiber-reinforced polyamide (PA6). Different pressure and temperature levels during HTC were tested to determine the overall effect on the mechanical behavior and material crystalline composition. Treated, carbon fiber-reinforced PA6 samples were analyzed using differential scanning calorimetry, X-ray diffraction, thermogravimetric analysis, scanning electron microscopy, and three-point bending testing. When considered with respect to as-printed samples, an HTC temperature of 190 °C combined with 80 psi pressure resulted in an increased flexural modulus and strength …

Greek Key-Inspired Fractal Metamaterials With Enhanced Flexibility And Energy Absorption., Zhennan Zhang

Electronic Theses and Dissertations

Architected materials with intricate three-dimensional (3D) geometries offer unique properties and functionalities but face challenges in manufacturing costs and complexity. This research explores the integration of simple 2D Greek Key-inspired lattices into fractal designs to achieve exceptional mechanical performance. Using 3D printing and kerfing, these fractal structures demonstrate enhanced flexibility and energy absorption capabilities. Through three-point bending and in-plane tensile tests, the 2D fractal lattices exhibited a 600-fold reduction in bending force and a tensile stretch capacity of up to 520%, significantly outperforming brittle parent materials. Out-of-plane compression tests revealed a five-fold increase in energy absorption compared to honeycomb structures, …

Development And 3d Printing Of Glass Fiber And Carbon Fiber Reinforced Shape Memory Polymer Composites For Structural Applications., Krishna Sai Aparna Munjuluri

Electronic Theses and Dissertations

This study aims at the development of shape memory polymer composites with two types of reinforcements, milled glass fibers, and chopped carbon fibers, for potential structural applications in aircraft and automotive industries. Glass fiber-SMP composites were made at fiber loading wt.% of 0%, 5%, 10%, and 20%. In contrast, carbon fiber-SMP composites were made at fiber loading wt.% of 0%, 5%, 10% and 15%. The feedstocks were extruded into filaments and characterized by their physical, rheological, chemical properties and morphologies. Fused Filament Fabrication 3D printing was used to manufacture specimens for mechanical testing of hardness and flexural properties. The findings …

Natural Fiber Reinforced Composites For Sustainable Additive Manufacturing., Athira Nair Surendran

Electronic Theses and Dissertations

Carbon fiber is widely known for its exceptional strength, making it a sought-after material in composite manufacturing, especially with thermosets and thermoplastics. Its major applications span aerospace, wind turbines, sports equipment, automotive interior and exterior parts, robotics and medical equipment. Recently, carbon fiber filament manufacturing has gained attention due to the availability of desktop 3D printers and the versatility and customizability that comes with the realm of 3D printing. Commercial carbon fiber production, primarily from polyacrylonitrile (PAN), is energy-intensive and derived from crude oil, contributing to significant environmental impacts and poor recyclability. Alternatively, lignocellulosic natural fibers present a possible sustainable …

Development And Processing Of Shape Memory Polymer Composites (Smpcs) For Application In Structural Robotics And Robotic Sensors., Kavish Sudan

Electronic Theses and Dissertations

Shape Memory Polymers (SMPs) have attracted significant attention since their introduction in the 1980s due to their remarkable ability to regain their original shape from a temporarily deformed state when exposed to an external stimulus, typically heat. This shape memory effect, driven by thermal transitions such as the glass transition temperature (T_g) or melting temperature (T_m), has made SMPs highly attractive for applications in soft robotics, aerospace, and biomedical devices. However, SMPs face challenges such as limited mechanical strength, thermal stability, and electrical conductivity, which hinder their broader adoption in advanced applications. To address these challenges, …

Development Of A Multi-Use Modular Microfluidic Platform Using 3d Printing, Carson Emeigh

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Microfluidic lab-on-a-chip (LoC) technology has driven numerous innovations due to their ability to perform laboratory-scale experiments on a single chip using microchannels. Although LoC technology has been innovative, it still suffers from limitations related to its fabrication and design flexibility. Typical LoC fabrication, with photolithography, is time consuming, expensive, and inflexible. To overcome the limitations of LoC devices, modular microfluidic platforms have been developed where multiple microfluidic modules, each with a specific function or group of functions, can be combined on a single platform. Modular microfluidics have overcome some of the limitations of LoC devices, but currently, their fabrication is …

Surgical Navigation In Image-Guided Transoral Robotic Surgery, Yuan Shi

Dartmouth College Ph.D Dissertations

Transoral robotic surgery (TORS) is a minimally invasive approach in treating head and neck cancers and has demonstrated improved surgical outcomes with reduced morbidity when compared to traditional open surgery. However, the lack of haptic feedback makes it more difficult to assess the tumor extent and locate critical structures (e.g., artery and nerves). In standard-of-care TORS, preoperative imaging is used as guidance; however, it becomes inaccurate intraoperatively: the patient’s neck is hyper-extended, surgical instruments are introduced, and soft tissues deform significantly. As a result, the surgeon is required to mentally predict intraoperative deformation, which can lead to bleeding complications and …

Wire Texture C-Axis Distribution Of Strontium Ferrite/Pa-12 Extruded Filament, Gabriela Espinosa-Rodriguez, Oluwasola Arigbabowo, Jonathan Alvarado, Jitendra Tate, Wilhelmus J. Geerts

Mechanical Engineering Faculty Publications

The magnetic anisotropy of strontium ferrite (SF)/PA12 filament, a popular hard magnetic ferrimagnetic composites that is used for 3D-printing of permanent magnets, is studied by vibrating sample magnetometry. The studied filaments have a composition of SF/PA-12 thermoplastic composite with a 40% wt.  ratio of SF. SF particles are non-spherical platelets with an average diameter of 1.3 um and a diameter to thickness ratio of 3. Filaments are produced by a twin-screw extruder and have a diameter of 1.5 mm. SEM images show that the SF particles are homogeneously distributed through the filament. VSM measurements on different parts of the filaments …

A Review On Additive Manufacturing For Aerospace Application, Radhika C, Ragavanantham Shanmugam, Monsuru Ramoni, Gnanavel Bk

Manufacturing & Industrial Engineering Faculty Publications

Additive manufacturing, a cutting-edge technology often colloquially known as 3D printing, is a transformative process used to meticulously fabricate complex components by adding material layer upon layer. This revolutionary manufacturing method allows for precise control and customization, making it a go-to choice in various industries, from aerospace to healthcare. The adroitness of additive manufacturing in creating a complex geometry as a whole is very much harnessed by the aerospace Industry. Generating a component using additive manufacturing involves optimal design, methods, and processes. This review gives a broad knowledge in developing a part or product by choosing the appropriate design, method, …

Computational Modelling Of A Triaxial Vibrating Sample Magnetometer, Leo Rodriguez, Arjun Sapkota, Jonathan Alvarado, Jitendra S. Tate, Wilhelmus J. Geerts

Mechanical Engineering Faculty Publications

Magnetic Field Assisted Additive Manufacturing (MFAAM) enables 3D printing of magnetic materials of various shapes which exhibit a complex anisotropy energy surface containing contributions generated from different origins such as sample, particle, and agglomerate shape anisotropy, flow and field induced anisotropy, and particle crystal anisotropy. These novel magnet shapes require the need to measure the x, y, and z components of the magnetic dipole moment simultaneously to fully understand the magnetic reversal mechanism and unravel the complex magnetic anisotropy energy surface of 3D printed magnetic composites. This work aims to develop a triaxial vibrating sample magnetometer (VSM) by adding a …

Generalizable Fugitive Carrier Method For 3d Printing Of Hydrogels, Hakan Arslan

Mechanical and Aerospace Engineering Dissertations - Archive

Hydrogels, with physical characteristics resembling biological soft tissues, hold great potential for bioinspired and biomedical applications. However, using them in additive manufacturing systems has challenges because of their poor mechanical and rheological properties. In response to these challenges, we introduce a fugitive carrier method, a novel and generalizable approach for materials incompatible with pneumatic-based extrusion three-dimensional (3D) printers. Our developed fugitive carrier method allows the 3D printing of a broad spectrum of hydrogel precursors with low viscosity while retaining their inherent properties. This technique has been successfully demonstrated by creating biomimetic structures with anisotropic and programmable systems utilizing temperature-sensitive hydrogel …

Advancements And Challenges In Additively Manufactured Functionally Graded Materials: A Comprehensive Review, Suhas Alkunte, Ismail Fidan, Vivekanand Naikwadi, Shamil Gudavasov, Mohammad Alshaikh Ali, Mushfig Mahmudov, Seymur Hasanov, Muralimohan Cheepu

Engineering Technology Faculty Publications

This paper thoroughly examines the advancements and challenges in the field of additively manufactured Functionally Graded Materials (FGMs). It delves into conceptual approaches for FGM design, various manufacturing techniques, and the materials employed in their fabrication using additive manufacturing (AM) technologies. This paper explores the applications of FGMs in diverse fields, including structural engineering, automotive, biomedical engineering, soft robotics, electronics, 4D printing, and metamaterials. Critical issues and challenges associated with FGMs are meticulously analyzed, addressing concerns related to production and performance. Moreover, this paper forecasts future trends in FGM development, highlighting potential impacts on diverse industries. The concluding section summarizes …

Energy Efficiency In Additive Manufacturing: Condensed Review, Ismail Fidan, Vivekanand Naikwadi, Suhas Alkunte, Roshan Mishra, Khalid Tantawi

Engineering Technology Faculty Publications

Today, it is significant that the use of additive manufacturing (AM) has growing in almost every aspect of the daily life. A high number of sectors are adapting and implementing this revolutionary production technology in their domain to increase production volumes, reduce the cost of production, fabricate light weight and complex parts in a short period of time, and respond to the manufacturing needs of customers. It is clear that the AM technologies consume energy to complete the production tasks of each part. Therefore, it is imperative to know the impact of energy efficiency in order to economically and properly …

Additive Manufacturing Of Composites For Sensing And Harsh Environments Application, Md Sahid Hassan

Open Access Theses & Dissertations

Composite materials are made by combining two or more materials, such as fibers and resins to create a material system that has improved mechanical and physical properties compared to its individual components. The use of 3D printing technology in composite manufacturing allows for the creation of complex and custom shapes with precise control over the placement of the materials. This makes it possible to create composite parts with enhanced performance characteristics and reduced weight. The work presented in this dissertation lies in the design and development of highly flexible impact propagation sensor through material extrusion 3D printing technique. By using …

Analyzing The Effects Of Ultrafast Laser Processing On Mechanical Properties Of 3d-Printed Pla Parts, Darshan Pramodbhai Yadav

Theses and Dissertations

Recent advances in additive manufacturing technologies have already led to wide-scale adoption of 3D-printed parts in various industries. The expansion in choice of materials that can be processed, particularly using Fused Deposition Modeling (FDM), and the steady advancements in dimensional accuracy control have extended the range of applications far beyond rapid prototyping. However, additive manufacturing still has considerable limitations compared to traditional and subtractive manufacturing processes. This work addresses limitations associated with the as-deposited surface roughness of 3D-printed parts. The effects of roughness-induced stress concentrations were studied on ultimate tensile strength and fatigue life. The samples were manufactured using a …

Damage Detection With An Integrated Smart Composite Using A Magnetostriction-Based Nondestructive Evaluation Method: Integrating Machine Learning For Prediction, Christopher Nelon

All Dissertations

The development of composite materials for structural components necessitates methods for evaluating and characterizing their damage states after encountering loading conditions. Laminates fabricated from carbon fiber reinforced polymers (CFRPs) are lightweight alternatives to metallic plates; thus, their usage has increased in performance industries such as aerospace and automotive. Additive manufacturing (AM) has experienced a similar growth as composite material inclusion because of its advantages over traditional manufacturing methods. Fabrication with composite laminates and additive manufacturing, specifically fused filament fabrication (fused deposition modeling), requires material to be placed layer-by-layer. If adjacent plies/layers lose adhesion during fabrication or operational usage, the strength …

Northrop Grumman Collaboration Project, Nikkia Psomas-Sheridan, Santiago Robles, Ben Elkayam, Benjamin Ulfhake

Mechanical Engineering

The Northrop Grumman Collaboration Project (NGCP) is a collaborative club project sponsored by Northrop Grumman for the students of Cal Poly San Luis Obispo (CPSLO) and Cal Poly Pomona (CPP) to create a fleet of vehicles to aid in the simulated rescue of stranded hiker. The CPSLO club is responsible for delivering an autonomous flight vehicle that can suppress a fire and retrieve a payload. Mechanical Design Team of the CPSLO team was responsible for the design of the frame, electronics housing, and payload and fire suppression systems.

Exploring Methods For Recycling Filament Waste In 3d Printing, Max Rios Carballo

Publications and Research

The goal of the current study is to investigate cutting-edge techniques for recycling filament waste from 3D printing procedures. Appropriate waste management techniques are required to reduce this trash's harmful environmental consequences. The goal of the project is to look at new methods for recycling filament waste in order to minimize disposal and encourage reuse. To acquire data from pertinent papers and research, a thorough literature review methodology was used. The findings show that this issue may be resolved utilizing a variety of recycling techniques, including shredding, melting, and re-extrusion. The type of filament waste and the intended goal will …