Manufacturing Commons^™

Usa Boccia Ball Ramp For Athletes With Quadriplegia, Alissa A. Koukourikos, Matthew Lee, Nathan Bernards

Mechanical Engineering

In this report, the design process in creating an assistive device for Boccia Classification 3 (BC3) players is outlined. The initial research steps, including research into the rules of the game, capabilities of the players, and existing products is documented to show where ideas for the product stemmed from. This transitions into requirements that the sponsor requested, and preliminary designs and ideas for the product. Finally, this report explains the details of the final design, which has been analyzed for safety, ease of use, and ability to function under different conditions. The processes of manufacturing and testing will also be …

Dyno-Mite Redesign, Brandon Joseph Miller, Daniel Robert Hoffman, Richard Demedici Young

Mechanical Engineering

The Cal Poly Mechanical Control Systems Laboratory currently employs an outdated device, known as the Motomatic, to teach students about various motor characteristics and control methods. These include open-loop vs. closed-loop control, speed vs. position control, and DC motor response curves. The current device does not function properly and produces unreliable data due to overwhelming non-linear effects such as stiction and shaft misalignment. Our team was tasked with designing a replacement device that retains many of the same educational goals as the original lab procedure, while also adding new educational goals pertaining to the device system dynamics. The new apparatus, …

Surface Topography Formation And Thermographic Analysis In Laser Polishing Of H13 Tool Steel, Joshua D. Miller

Electronic Thesis and Dissertation Repository

Laser polishing, in its simplest form, is the melting of a small layer of material via laser radiation. This creates a small molten pool which is re-distrusted across the surface, resulting in a much smoother finished surface. Although this process has been around for decades now, there has been a recent insurgence into industrial applications. Despite this, the phenomena that occur during the process are still not fully understood. Therefore, increasing the knowledge surrounding the process would be ideal.

To accomplish this, various input parameters of the process are altered to analyze the effect on the finished polished surface. Through …

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 …

Leading Edge Boundary Layer Suction Device For The Cal Poly Rolling Road Wind Tunnel, Daniel C. Glover, Liam M. Madden, Robert J. Cabri

Mechanical Engineering

Over the course of three quarters from Fall of 2016 to Spring of 2017, our team designed and built a boundary layer suction device. The boundary layer suction device has three main functions: a scoop that redirects most of the boundary layer air out of the wind tunnel, fans that suck the remaining boundary layer air through a porous plate and ducting and out of the wind tunnel, and a transition bridge that transitions the remaining air smoothly onto the rolling road. The wind tunnel is owned by Cal Poly and the rolling road is a new addition to it. …

Pedal-Powered Drivetrain System, Geremy J. Patterson, Callaghan Fenerty, Bradley Welch

Mechanical Engineering

No abstract provided.

Additive Manufacturing For Post-Processing, Nathan D. Goodwin, Andrew Furmidge

Mechanical Engineering

Additive Manufacturing for Post Processing (AMPP) is a team comprised of two Cal Poly Mechanical Engineering students: Nathan Goodwin and Andrew Furmidge. The project is focused in the area of metal additive manufacturing (AM) machines, which are still a developing technology. Improvements have been made to the quality of the machines in the past years, but many limitations still exist. One of these is the inability to print parts that are larger than the build volume. In an effort to solve this problem, whole parts are divided into pieces that are printed individually. This team’s senior project is to create …

Bear Minimum: Ultralight Composite Bear Canister, Rama B. Adajian, Adam C. Eisenbarth

Mechanical Engineering

The ultralight backpacking community needs a strong, easy to use, safe bear canister that is lighter than current market products for trekking in the backcountry. A full design of the lid for the bear canister is to be completed. This includes the locking mechanism to ensure it is bear proof, the interface between the lid and the canister, and the structure of the lid so it passes the strength and weight specifications. The lid, along with the already designed canister body, is to be manufactured with formal documentation. The lid will initially be tested separately and then with the canister …

Feasibility Of Using 3d Printed Molds For Thermoforming Thermoplastic Composites, Sunil Bhandari

Electronic Theses and Dissertations

This thesis presents a novel combined experimental and numerical mechanics approach for characterizing 3D printed thermoplastic materials by the fused deposition modeling process for thermoforming thermoplastic composites. The implications of this work are:

1. a methodology for model-based performance evaluation of 3D printed structural parts, and
2. an improved design of 3D printed molds for composites manufacturing, which has potential for material innovations and scaled-up applications in additive manufacturing.

The thesis formulates basic criteria for selection of thermoplastic polymer used for the 3D printed mold based on forming temperatures. The thesis creates a lattice and shell finite element model of the 3D …

Lab Toner Vacuum Cleaner Caddy, Treavor C. Johnson Mr., Robert K. Davis Mr., Spencer K. Sanders Mr., Erin M. Miller Ms.

Chancellor’s Honors Program Projects

No abstract provided.

The Intersection Of Manufacturing Technologies And School Music Programs, Leslie Prunier

University Scholar Projects

The objective of this project is to design and manufacture a musical instrument, a marching baritone horn, out of plastic. It is constructed out of both PVC pipe and 3D-printed components. Utilizing this project’s documentation, a high school student could use a 3D printer and other basic tools to make their own musical instrument for a fraction of the cost of purchasing one. This documentation will produce a horn tuned in the key of B flat with one functioning valve, and suggestions for future work to make the other two valves functional as well.

Built-In Bicycle Rack For Cars, Scott A. Hansberry

All Undergraduate Projects

Transporting a bicycle after riding somewhere and then needing to be pickup can be problematic. Bicycles will not fit in most vehicles without removing components. There is also the risk of damaging the inside of the vehicle. Expecting everyone to have a bike rack for their vehicle is unrealistic because the bike rack could be considered unappealing visually, take up to much space in the trunk, or limit the vehicle owner’s access to the trunk. The solution to this problem is a bike rack that mounts onto your car and then mounts your bike onto the rack. Most people don’t …

Pin Router Duplicator, Daniel Phan

All Undergraduate Projects

The purpose of this project is to develop a pin router duplicator to accurately produce guitar bodies, necks, and fret boards. The pin router duplicator is designed to speed up the production process for the class Lean Manufacturing (MET 345), offered at Central Washington University. In the class, students learn how to work as a team to improve the way a woodshop is ran. In Lean Manufacturing, guitar bodies, necks, and fret boards are produced by using a CNC router. For this project, the motivation is to increase production by reducing production time. Accuracy and repeatability is also taken into …

High Accessibility Cabinet Insert, Matthew Leal

All Undergraduate Projects

Watching grandparents and parents get older, the struggle of day-to-day activities generally increases. One of the most recurring issues the older generation experiences nearly daily is their inability to reach dishes, glassware, and other things on the topmost shelves of a kitchen. Not only is it difficult for them to use things such as stepstools, it also becomes increasingly dangerous. With age, a fall from any height could be catastrophic. With this scenario in mind, a user-friendly cabinet insert would be a very effective way to combat this issue. However, many existing models of cabinet designed to fit these requirements …

H.F. Hauff Outrigger: Vertical Arm, Juan Tovar

All Undergraduate Projects

H.F. Hauff is a company based out of Yakima which specializes in farming equipment. One of their products is a trailer which has a wind machine attached to it. In order to keep the fan’s thrust from tipping the trailer over, the trailer needs outriggers to extend out. The outriggers also serve as a way to level out the trailer in uneven surfaces. The outriggers are what needed to be designed. This portion of the project was the vertical arm which extends from the horizontal arm, and goes towards the ground to raise the trailer. The project consisted of three …

Chocolate Bar Wrapping Machine, Austin M. Hoff, Daniel R. Trepke, Caleb B. Krichbuam

Williams Honors College, Honors Research Projects

Gilbert Chocolates has proposed to manufacture a machine to wrap chocolate bars. This machine is intended to replace two people wrapping the chocolate bars by hand, which is a time consuming method. This is especially apparent between October and January when the workers are working long hours in preparation for the Christmas rush of customers. Currently wrapping a bar takes about a minute and Gilbert Chocolates wants this time reduced down to 20-30 seconds. The budget for this project is set at $1000, and is being funded by the company. This machine needs to fit in a cubic foot of …