Computer-Aided Engineering and Design Commons^™

Cal Poly Fluid Powered Vehicle Challenge 2025/2026, Ethan Malachi Nejame Zeiset, Christian Anthony Cuamani, Daniel Chacon-Bizarro, Marcus Minera, Bradley Hansell

Mechanical Engineering

In this Final Design Report, the Cal Poly Fluid Power Vehicle Challenge Contending Team competed in Sun Hydraulics’ 2026 Fluid Powered Vehicle Challenge. The objective of the competition is to expose college students to the fluid power sector, the “hidden giant” of the engineering industry. Specifically, student teams are tasked with the development of a human-powered, fluid-driven vehicle for use in various competitive settings. The team prioritized the optimization of an existing prototype for simplicity, ease of maintenance, and reliability during the competition. The existing prototype exhibited issues related to the main frame’s deflection under load, a lack of gear …

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Parts, Logan Trimmer

Harrisburg University Other Works

Presentation covering the broad strokes of the project. The goal was to prove the viability of hybrid/additive manufacturing for high stress automotive applications. This project focused on recreating a piston from an old engine to examine if hybrid manufacturing could be used for such applications. On a small scale, hybrid manufacturing was able to be more cost effective if the costs of the equipment and electricity were ignored. The decision to ignore those costs came from the inability to find accurate prices for industrial casting.

Akron Soap Box Derby Super Kids Car, Alexis Schultz, Cooper Sites, Sean Stevenson

Williams Honors College, Honors Research Projects

This project aims to redesign the All-American Soap Box Derby Super Kids vehicle to enhance safety, accessibility, and performance while maintaining full compliance with official regulations. The Super Kids program enables children with physical and cognitive disabilities to race alongside a co-pilot, but the current vehicle design presents challenges in stability, entry/exit accessibility, and control—especially following recent regulation changes that increased vehicle speed. The redesigned car will focus on improved ergonomics, lightweight construction, and structural integrity within a $1,000 budget and a 165 lb weight limit.

An iterative engineering design process will guide the project through research, CAD modeling, FEA …

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Components, Logan Trimmer

Harrisburg University Other Works

The goal of this research was to establish the viability of using hybrid manufacturing for automotive applications. By verifying that high-stress components can be created, it can be assumed that any other lower stress part could be made to match the strength requirements. A limiting factor of adoption for hybrid manufacturing is how new the technology is. Studies on time and cost were performed allowing for comparisons with traditional manufacturing technologies (casting, forging, milling) used in automotive applications. This research utilized a Haas Automation UMC750 5-axis CNC mill with a Meltio laser wire direct energy deposition attachment. Fusion 360 was …

Shape Memory Behavior In Medium To High Entropy Shape Memory Alloys: Design, Prediction, And Experimental Analysis, Hatim Raji

Theses and Dissertations

This dissertation provides a data-driven system integrating synthetic data generation and machine learning (ML) techniques to create multicomponent SMA compositions with specific transformation temperatures (TTs). Models were trained to represent the nonlinear dependencies influencing martensitic transformation behavior by using elemental, thermodynamic, and process-related aspects. The capacity of the ML models on medium entropy NiTiHfPd and high entropy NiTiHfZrCu systems accuracy was confirmed by experimental validation showing TTs closely matched with model outputs.

Mechanistic Insights Into Polymer-Assisted Graphene Exfoliation: The Roles Of Velocity, Adhesion, Cohesion, Temperature, Peeling Mode, And Edge Defect Via Coarse-Grained Molecular Dynamics, Linjiale Dai

All Theses

Graphene exfoliation is a critical step in the fabrication of high-quality graphene

layers. However, the underlying fracture mechanisms remain poorly understood. In this

work, I employed coarse-grained (CG) molecular dynamics (MD) simulations to

investigate how factors such as interfacial binding energy, substrate cohesion, temperature,

peeling mode, and edge defects influence the outcome of the exfoliation process. To model

polymer-assisted mechanical exfoliation, I used a finite-size system in which multilayer

graphene (MLG) is sandwiched between two thin polymer films. Leveraging the

spatiotemporal efficiency of the CG model, I performed fifty simulation iterations per

parameter set and analyzed the results from a …

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 …

Design And Development Of A Rapid Tensile Quench Rig, Tyler Jewell, Justin Naylor

Williams Honors College, Honors Research Projects

This report outlines the design process and implantation of a tensile quenching rig that incorporated forced convection and a frequency generator. When any metal is quenched, a vapor barrier forms around it. When this happens, it limits the heat flux that may occur until the barrier turns into just nucleate boiling. The vapor barrier acts as an insulator and causes the heat flux to fluctuate, causing uneven hardening which would limit the use of some materials. To combat this effect, we are trying to use forced convection, and something new, which is adding high frequency waves into the quenching process. …

Blade Design And Validation Of Hydrokinetic Turbine To Harvest Water Current Energy, Setare Sadeqi

LSU New Orleans Theses and Dissertations

The innovative aspect of this research lies in the careful integration of cutting-edge technologies throughout the entire process of designing, fabricating, and testing the carbon fiber propeller for the 3-bladed horizontal axis ocean current turbine (OCT). SolidWorks software played a pivotal role in the initial design phase, enabling a meticulous and precise modeling of the propeller's geometry. The utilization of SolidWorks allowed for a detailed exploration of various design parameters, ensuring that the propeller's structure and form were optimized for performance in ocean current conditions. Moving beyond the realm of virtual design, the choice of carbon fiber as the fabrication …

A Manufacturing-To-Response Pathway For Manufacturing Optimization Of Carbon Fiber Reinforced Polymer Composite Structures, Madhura Limaye

All Dissertations

Over the past decade, there has been an increased adoption of thermoplastic and thermoset based continuous carbon fiber reinforced polymer (CFRP) composites for structural applications in several industries. Among the different manufacturing methods, thermoforming process for thermoplastic based continuous CFRP’s offer a major advantage in reducing cycle times for large scale productions. Similarly, out-of-autoclave curing process for thermoset based continuous CFRP’s using heated tooling enables production of large composite structures. However, these manufacturing processes can have a significant impact on the structural performance of parts by inducing undesirable effects. These effects include inhomogeneous fiber orientations, thickness variations, and residual stresses …

A Study On High-Frequency Bending Fatigue, Microhardness, Tensile Strength, And Microstructure Of Parts Made Using Atomic Diffusion Additive Manufacturing (Adam) And Additive Friction Stir Deposition (Afsd), Hamed Ghadimi

LSU Doctoral Dissertations

This dissertation reports the findings of several studies on the mechanical and microstructural properties of parts made using atomic diffusion additive manufacturing (ADAM) and additive friction stir deposition (AFSD). The design of a small-sized bending-fatigue test specimen for an ultrasonic fatigue testing system is reported in Chapter 1. The design was optimized based on the finite element analysis and analytical solution. The stress–life (S–N) curve is obtained for Inconel alloy 718. Chapter 2 presents the findings of ultrasonic bending-fatigue and tensile tests carried out on the ADAM test specimens. The S-N curves were created in the very high-cycle fatigue regime. …

Schaeffler E-Axle Value Engineering, Andrew Powers

Williams Honors College, Honors Research Projects

This project aims to design a manufacturable E-Axle end housing that improves system performance while reducing cost. The project is focused on utilizing Schaeffler's manufacturing competencies to achieve a simple assembly with a significant reduction in cost per part, while using existing machines or processes within the company. The design development process will follow the conceptual design stage through Finite Element Analysis and classical engineering calculations. Cross-functional design reviews will be conducted to ensure that agreement can be reached on the manufacturing feasibility of the design. Concepts will be entered in a decision analysis sheet to identify the best one …

The Center For Centering Dome, Olek Piechaczek, Ryan M. Scharf

Architectural Engineering

The Center for Centering seeks to create a large-scale healing center, conducive to individual centering of the mind and body. This mobile installation provides a relaxing, enclosed space while still maintaining a connection to the outdoors. The clients liked the idea of having a pop-up installation that could be easily set up as a touring display. With a deadline for installation looming in June 2022, a team of students had five months to design and manufacture the structure.

In winter 2022, the students developed custom geometry to minimize the number of individual parts and built a ¼ scale model of …

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 …

Novel Thermal Coating For High-Speed Airplanes, Abinash Satapathy, Lakshay Battu, Liam Watson, Nazanin Rajabi

Symposium of Student Scholars

In comparison to various other materials, Carbon Fiber, specifically Carbon Fiber Reinforced Polymers (CFRP), is pre-eminent amongst other materials for use on aeronautical systems. Due to its high specific strength (strength-to-weight ratio), CFRP is prominent for carrying heavy loads while maintaining a lightweight build. However, when influenced by heat resulting from air resistance, CFRP is known to undergo serious degradation that would significantly decrease the effectiveness of the polymers. To prevent this degradation and maintain the strength of the CFRP, thermal protective layers (TPLs) are designed to shield the CFRP from heat exposure. This research is focused on the examination …

Method Of Embedded Imperfections For The Direct Simulation Of Deformation Instabilities In Film-Substrate Structures, Siavash Nikravesh Kazeroni

Mechanical Engineering ETDs

In this dissertation, a novel finite-element methodology called “embedded imperfections” is proposed and employed for computationally simulating various types of deformation instabilities observed in film-substrate structures subjected to mechanical loading. The approach involves the incorporation of elements having distinctive material properties within the film-substrate interface. One can interpret this practice as a deliberate distribution of material defects within the numerical model. It has been shown that embedded imperfections not only can trigger the onset of instability, but also can lead to “direct” simulation of deformation instability problems in that primary and subsequent instability modes can all be captured in a …

Microscale Transverse Compression Modeling: A Comparative Study Of The Analytical Mac/Gmc Methods To Experimental Results, Emily Zeitunian

Dissertations, Master's Theses and Master's Reports

Composite materials require a multi-scale approach to fully understand its behavior. At the micro level, material behavior analysis is conducted most often using numerical or analytical approaches. These models, however, require validation from experimental data to ensure material predictions are accurate. This study compares a semi-analytical micromechanical analysis tool, MAC/GMC, to experimental results of in-situ microscale transverse compression testing conducted at AFRL facilities. Effective properties, stress-strain curves, stress and strain fields, and damage predictions are compared with experimental outputs. Both generalized method of cells (GMC) and high-fidelity generalized method of cells (HFGMC) theories implemented within MAC/GMC show results that agree …

A Single-Stage Passive Vibration Isolation System For Scanning Tunneling Microscopy, Toan T. Le

Master's Theses

Scanning Tunneling Microscopy (STM) uses quantum tunneling effect to study the surfaces of materials on an atomic scale. Since the probe of the microscope is on the order of nanometers away from the surface, the device is prone to noises due to vibrations from the surroundings. To minimize the random noises and floor vibrations, passive vibration isolation is a commonly used technique due to its low cost and simpler design compared to active vibration isolation, especially when the entire vibration isolation system (VIS) stays inside an Ultra High Vacuum (UHV) environment. This research aims to analyze and build a single-stage …

Mini Rc Baja Car, Jason Schindler

All Undergraduate Projects

Incorporating each aspect of engineering incorporated into a senior project is difficult. That is why an RC Baja car is a great senior project for Mechanical Engineering students. The approach that students must take to design, construct, and test the car is to set parameters, and to make overall goals that can be easily measured. These goals include, but not limited to things like a $700 budget and the ability to withstand a 1-foot drop to a flat surface on all four wheels simultaneously. First, the design must meet the specifications and rules that are set previously. This ensures that …

Hydraulic Balsa Wood Rising Bridge, Kaitlyn Greenfield

All Undergraduate Projects

What is the solution to allowing tall vessels to navigate past a vehicle bridge that is less than 10 [ft] above the water? To answer this question, a balsa wood bridge was designed, constructed, and tested. The bridge needed to articulate by mechanical means, allow for travel through the bridge, and be able to withstand ample force while the main structure only being constructed of balsa wood and glue. The project was analyzed in sections. These sections include: the bridge structure and its members, the hydraulic lift, and the pins needed for the bridge and hydraulic lift to operate. The …

Mechanical Footstep Power Generator, Mohammed Saleh Aljohani, Faisal Alonazi

All Undergraduate Projects

Mechanical Footstep Power generator

By Author: Mohammed Aljohani

Abstract

Modern technology is focusing on newer and better sources of energy. Among the important areas are power generation methods since electricity has become part of our lives. Various researchers have conducted surveys to find out the feasibility of converting renewable kinetic energy into electricity. Some of the works done in the past emphasized the selection of suitable materials and power generation systems designs that appear complicated and expensive. To ensure there is cost efficiency and energy efficiency better power generation systems need to be embraced.

The footstep power generator is a …

Buckling Load Study On Pop Nut (Rivet) Using Finite Element Analysis, Saurabh Shankar Shegokar

Dissertations, Master's Theses and Master's Reports

This study highlights the material behavior in riveting operation that includes buckling load analysis using ABAQUS. Finite Element Analysis is used to find the buckling load vs. Displacement results and validated with the results obtained in physical testing of rivet (POP Nut). A mesh sensitivity study is performed using ABAQUS to understand the optimum mesh size for this analysis. An axisymmetric model with contact properties is created and simulated to reduce the simulation time using ABAQUS. The results obtained through Finite Element Analysis show a good resemblance with the testing results. Design changes were suggested to achieve better results that …

Development Of Experimental And Finite Element Models To Show Size Effects In The Forming Of Thin Sheet Metals, Jeffrey D. Morris

LSU New Orleans Theses and Dissertations

Abstract

An experimental method was developed that demonstrated the size effects in forming thin sheet metals, and a finite element model was developed to predict the effects demonstrated by the experiment. A universal testing machine (UTM) was used to form aluminum and copper of varying thicknesses (less than 1mm) into a hemispherical dome. A stereolithography additive manufacturing technology was used to fabricate the punch and die from a UV curing resin. There was agreement between the experimental and numerical models. The results showed that geometric size effects were significant for both materials, and these effects increased as the thickness of …

Reinventing The Wheel, Esther K. Unti, Ahmed Z. Shorab, Patrick B. Kragen, Adam M. Menashe

Mechanical Engineering

Reinventing the Wheel selected tires and designed wheels for the 2018 Cal Poly, San Luis Obispo Formula SAE combustion vehicle. Available tire options were evaluated for steady-state and transient performance as well as vehicle integration. A single-piece composite wheel with hollow spokes was designed to meet stiffness, strength, and tolerance requirements. A detailed study of wheel loading and geometric structural efficiency was performed. Finite element analysis was used to iterate the geometry and laminate. A two-piece male mold was designed and machined to manufacture the wheel. Removable silicone inserts were used to create the hollow spokes.

Analysis Of The Low-Cycle Fatigue Behavior Of Silicone Rubber For Biomedical Balloons, Chase Cooper

Materials Engineering

The development of a medical drug delivery device that allows for the deployment drugs into the adventitial tissue of blood vessels requires the inflation of a silicone elastomer. The inflated silicone must be able to consistently endure multiple loading cycles without failing so that the device can operate reliably. There are multiple methods of processing the silicone for the device and the goal of this study is to examine the effect of the various processing methods on the characteristics of the silicone. The Dynamic Mechanical Analysis Machine (DMA) is used to model the conditions of the device’s application by performing …

Structural And Aerodynamic Design, Procedure And Analysis Of A Small V-Shaped Vertical Axis Wind Turbine, Odari J. Whyte

College of Graduate Studies: Theses & Dissertations

Over the last two decades there has been a renewed interest in Vertical Axis Wind Turbines. This turbine configuration though unpopular for large-scale generation has found a niche market in the way of offshore energy harvesting. However, offshore wind has its challenges. In this thesis a detailed comprehensive study of a proposed V-shaped vertical axis turbine rotor is performed in order to examine its structural and aerodynamic characteristics. The design met and exceeded the safety parameters establish for test bed operation, showing a factor of safety of 1.87 with regard to fatigue stress response. A satisfactory fatigue stress design life …

Thermal-Fatigue And Thermo-Mechanical Equivalence For Transverse Cracking Evolution In Laminated Composites, Javier Cabrera Barbero

Graduate Theses, Dissertations, and Problem Reports (ETD)

Carbon fiber reinforced plastics (CFRP) are potential materials for many aerospace and aeronautical applications due to their high specif strength/weight and a low coeffcient of thermal expansion (CTE) resulting in a high long-term stability. Among candidate structures, the re-entry reusable launch vehicles (RLV), the fuel oxidant storage and transportation at cryogenic temperature, space satellites, and aircraft structure (frame, wings, etc...) can be highlighted. However, CFRP are prone to internal damage as a result of high residual stresses and thermal fatigue loading. In this study, micro-cracking damage evolution in laminated composites subjected to monotonic cooling and thermal cyclic loads is developed …

Development Of The End-Effector Of A Cable-Driven Parallel Manipulator For Automated Crop Sensing, Iman Salafian

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

A four cable-driven parallel manipulator (4CDPM), consisting of sophisticated spectrometers and imagers, is under development for use in acquiring phenotypic and environmental data over an acre-sized maize field. This thesis presents the design, controls, and testing of two sub-systems in a 4CDPM: a Center of Mass Balance System (CMBS) and a Drop-Down System (DDS).

One of the factors that influences stability is the center of mass (COM) position of the end effector. An offset in COM can cause a pendulum effect or an undesired tilt angle. A center of mass balancing system is presented in this thesis to minimize the …

Development Of 3d Compression Molded Composite Primary Structure, Sean D. Tischler, Jacob H. Goldstein, Alea A. Perez

Mechanical Engineering

The work accomplished by the Black Gold team improved upon the carbon fiber compression molding research and information available on the Cal Poly San Luis Obispo campus. The team used the rear suspension rocker arm off a Ventana Alpino mountain bike as a design goal for this project. This research and body of work includes the methods used to design a compression molded part for complex part loading and shape. This extends to the process of choosing an appropriate layup process, in addition to benefits and drawbacks of the use of chopped fibers in compression molding. The research includes the …

Frontal Crash Analysis Of A Conformable Cng Tank Using Finite Element Analysis, Datta Sandesh Manjunath

Dissertations, Master's Theses and Master's Reports

The purpose of this study is to computationally model and analyze a Conformable Compressed Natural Gas (CNG) fuel tank for frontal crashes using Finite Element Analysis. Researchers have developed a CNG fuel tank, which is conformable, non-conventional and non-cylindrical. This tank increases cost efficiency, volumetric efficiency and cargo efficiency in CNG vehicle applications. A lightweight pickup truck (2015 Chevrolet Silverado) has been used to integrate the CNG tanks and field-testing has been conducted to demonstrate the application.

The report mainly focuses on the effective finite element modeling of the chassis, brackets and tanks using HYPERMESH and RADIOSS. The frontal crash …