Manufacturing Commons^™

Tagalong Trail, Sean Wahl, Jason Davis, Quinlan Stephens, Ryan Johnson, Vinh Vo

Mechanical Engineering

The Cal Poly mechanical engineering team working on the Path of Lights and Sounds for the Girl Scouts of California’s Central Coast has now completed their project. In the last quarter of their project, they were able to finalize their tile’s structural design while iterating through several electronics board designs. Through this iteration, they were able to create a final electronics board and designed a water-resistant enclosure to house the board. A new team member was added, allowing them to manufacture 28 tile structures and 30 electronics assemblies over the course of two and a half weeks. This proved to …

Cnc Retrofits, Fabian Samano, Murat Askin, Daniel Lonczak, Zane Campise

Mechanical Engineering

The Boxford CNC Lathe is a machine used for educational purposes. The goal of the CNC Retrofits project is to improve the Boxford MT2’s performance and functionality to enable Mr. Lonczak to manufacture customized ballpoint pens. Within this Final Design Review (FDR) document, we present design updates since the CDR and implementation/assembly techniques. This work culminates in a solution to Mr. Lonczak’s needs which is analyzed in three subsystems: main control, spindle position tracking, and user interface. Within this report, we show the results of each subsystem’s verification process. These results prove that the design concept was met by describing …

In-Situ Mechanical Tester, Andrrew Murach, Gustavo Marquez, Kosimo Tonn, Jake Vormbaum

Mechanical Engineering

Over the course of the 2022-23 Cal Poly SLO school year, a small tensile tester device was developed specifically for Dr. Long Wang to test thin film materials under a microscope and generate accurate force versus displacement graphs. A tensile tester was manufactured using purchased and machined components, electronics were consolidated in a separate box and connected, and a program and user interface were written to control the motion, provide custom inputs, and organize useful data for the researcher. Tests were conducted to compare the performance of the device to universal tensile testers available in the Composites lab. The device …

Novelty Ice Cream Assembly Prototype, Mason Sylvester, Logan Williamson, Alvaro Martinez, Adin Gilman-Cohen

Mechanical Engineering

Cool Beans USA is a novelty ice cream startup company founded by Keith Zachow. In the winter of 2022, our team began working with Mr. Zachow to develop a machine to automate parts of the production process for his product. This product consists of two hemispherical ice-cream cone shell halves filled with soft serve ice cream and pressed together. The assembled pods are around the size and shape of a small walnut and are intended to be sold in stores as a frozen finger food. At the time of project inception, this product was in its early stages and was …

Rotating Backing Brush, Caleb Savard, David Dalal, Max Allred, Mathis Weyrich

Mechanical Engineering

In the final steps of GAF’s shingle production process, small asphalt particles called fines are applied. Some fines adhere well to the shingle sheet, while others temporarily stick only to fall off the sheet further down the manufacturing line. As a result, the shingle plant floor is covered in fines that have fallen due to vibrations and gravity. The technicians and engineers at GAF want a cleaner working environment and to potentially reuse the loose fines. We are a senior project team that solved this problem by designing a system to remove and collect loose fines. In this document, the …

Eagle Medical Tray Denesting & Debris Removal Process, Nicholas Allen Ungefug, Noah Chavez, Susana Shu-Lin Okhuysen, Michael Augustine Pennington

Industrial and Manufacturing Engineering

Eagle Medical Incorporated is a contract medical device packaging and sterilization company. The company purchases thermoformed medical packaging trays, which maintain the sterility of medical devices, from various manufacturers. To ensure packaging quality and to prevent cleanroom contamination, Eagle Medical inspects and sterilizes each blister tray that they order. This process is an essential non-value-added activity that creates a bottleneck. Cleanroom employees must stop packaging medical devices and attend to the processing of blister trays and packaging solutions. The blister trays arrive at Eagle’s facility in nested stacks. Vibration and movement during shipping further compresses the stacks, which makes separation …

Interactive Lego Girl Scout Arm, Chris Suzuki, Emi Okuyama, Bryson Shores, Karina Sandoval

Mechanical Engineering

This Senior Project Report document outlines the senior design project for Girl Scouts of California’s Central Coast (GSCCC) led by a team of four Mechanical Engineering students at California Polytechnic State University, San Luis Obispo. The project encompasses the researching, designing, prototyping, and testing of a LEGO robotic arm for the Girl Scouts to learn more about STEM (Science, Technology, Engineering, and Mathematics) and provide support to each Girl Scouts cookie sales in their stores. Their goal was to build a LEGO robotic arm that will interact with customers at the Girl Scout stores and promote the girl scouts' interest …

Multifamily Complex Smart Locks For Property Management And Tenant Security, April Mills, Allen Chen, Dana Kumamoto, Michael Cook

Mechanical Engineering

Maintaining and managing hundreds of locks and physical keys for an apartment complex can be time consuming and costly, especially when the apartments turn over to new tenants. Our goal was to develop a smart door lock that is compatible with Obodo’s management app for apartment complexes to make accessing apartments secure and simpler for tenants and easier to manage for owners.

We designed and manufactured one smart door lock that is powered with four AA batteries and utilizes a dynamic NFC device and Bluetooth technology. The board can enter a sleep mode which reduces power consumption. The dynamic NFC …

8 Dof Quadrupedal Hopping Robot, Clayton T. Elwell, John Bennett, Tyler Mccue, Daniel Munic

Mechanical Engineering

The goal of our senior project was to fabricate an eight degree of freedom (DOF) prototypical quadrupedal robot, develop a controller than commands the quadruped to repeatedly jump 10 cm in the air, and fabricate a modular test stand to safely deploy our controller on the quadruped. The creation of a functional quadruped will bring attention to Dr. Siyuan Xing and Charlie Refvem’s research group, Cal Poly Legged Robots, and will give future Cal Poly undergraduate and graduate students a learning tool to explore dynamic control of biomimetic robotic systems.

Over the course of our senior project, we successfully manufactured …

Gaf Fiberglass Mat Slitter Blade Sharpener, Mark D. Breaux, Bradley M. Smith, Esteban Carrillo, Carlos Espinoza

Mechanical Engineering

This document contains an overview for the offline slitter blade sharpening system created for GAF to sharpen their current cutting tools in a timely and safe manner without hindering the timeline and production of their assembly line. This design was developed by four undergraduate students at from Cal Poly, San Luis Obispo. This document first investigates background information of any patents, current sharpening device, sharpening safety standards, or literature review that may be useful in a sharpening mechanism device. This document also contains our design concept prototype, which consists of three main features, the use of a top guard for …

Tensile Testing Environmental Chamber – Structural, Michael Ingel, Erik Soldenwagner, Austin Marshall, Lauren Schirle

Mechanical Engineering

Environmental chambers for tensile testing machines are used to study how a multitude of materials behave in extreme temperatures. These chambers provide the necessary information to innovate cutting edge technology for materials in fields such as aerospace. These chambers are often heavy and expensive requiring a significant amount of time and money just in the installation process alone. This report will serve to outline and define the design and fabrication of an environmental chamber, conducted by a team of four senior mechanical engineering students at California Polytechnic State University, San Luis Obispo. The goals of the project include a low-weight …

Inverted Fluorescence Microscope, Matthew B. Pfeiffer, Spencer George Hann, Thomas James Eggenberger, Trevor Lee Blythe

Mechanical Engineering

Team F13 is composed of Trevor Blythe, Spencer Hann, Matthew Pfeiffer, and Thomas Eggenberger. We are all majoring in mechanical engineering and in our final year of study here at Cal Poly San Luis Obispo. This project is a continuation of a 2019-2020 senior project. The previous team designed and built a functioning inverted fluorescence microscope (IFM) from scratch. This device was created as a lab tool for undergraduate students to be able to perform experiments on microfluidic devices constructed in Cal Poly’s Microfabrication Laboratory. Although substantially functional, several design constraints had not yet been met. Our team has improved …

Adjustable Height Pedestal Grinder Stand, Josef Zagorski, Zachary Wedel, Michael Sitar, Daniel Zevenbergen

Mechanical Engineering

Pedestal grinders are one of the most common machines found in machine shops today. The current industry standard for mounting a grinder is on a fixed single pillar, cast iron pedestal. A fixed pedestal allows for no vertical adjustment for shop users of different sizes and is a safety hazard. This report further defines this problem and proposes an iterative design process to meet the needs and wants of the customer. The adjustable-height pedestal grinder stand Senior Project team used this problem and design process to successfully complete the project within the allotted time. The first major deliverable and milestone …

Cnc Feed Drive Control, Ryan J. Funchess, Caleb P. O'Gorman, Nick J. Desimone, Juan M. Majano, Samuel K. Wong

Mechanical Engineering

This document serves as the Final Design Report (FDR) for a senior project developed by our team: four senior Mechanical Engineering students and one computer engineering student at California Polytechnic State University, San Luis Obispo (Cal Poly). While the project was completed for, and sponsored by, Professor Simon Xing of Cal Poly, the remainder of the university’s controls professors will be indirectly benefited from this project. Our goal was to design and implement a functional CNC Feed Drive to be used for educational demonstrations and data collection. This document discusses our early product research and benchmark goals, which established constraints …

Bull Outdoor Products - Electric Grill, Sofie M. Groberman, Makai J. Baker, James T. Andrews

Mechanical Engineering

Our senior design project team designed, assembled, and tested an outdoor electric grill. The sponsor for our project is Bull Outdoor Products, a high-end outdoor kitchen set, pizza oven, and grill company. We met with our sponsor to discuss project expectations and important product characteristics. We also researched the barbecue market and its customers to determine what grill characteristics are the most important. We learned which engineering specifications needed to be tested and outlined what our goals and overall objectives for this project are. With our background research and overall objectives in mind, we came up with different solutions through …

Project G.H.O.S.T., Matthew Morell, Austin Conrad, Zackeris Gordon, Conan Estes

Mechanical Engineering

Project G.H.O.S.T aimed to produce a model transmission with a control system for high performance/racing electric vehicles to utilize the full capability of the electric motor at higher speed applications. Current electric vehicles have a large amount of torque and use a fixed gear ratio that compromises between both high and low speeds with performance peaking around 65 miles per hour. A typical electric motor used in this application has approximately 1800 ft-lbs of torque up to 5,000 rpm. Past approximately 5,000 rpm, the torque rapidly drops off and so does the overall vehicle performance. Though transmissions exist that could …

2 Degree Of Freedom Robotic Leg, Oded Tzori, Henry Terrell, Adan Martinez

Mechanical Engineering

Professor Xing, an assistant professor at Cal Poly, proposed the 2 DOF Robotic Leg project for this quarter’s senior project class. The project is to build a robotic leg attached at the hip to a stand, which will be used as a teaching tool and eventually help develop Cal Poly’s very own robotic quadruped. Since this project has multiple uses after its completion, there are multiple customers that it must perform well for: the Cal Poly Mechanical Engineering (ME) Department, the ME Lab instructors, and the students. The Scope of Work (Sections 2 & 3) is composed of 2 main …

Cal Poly Supermileage Dynamometer, Jacob Randall, Nate Deffenbaugh, Kyle Milgram

Mechanical Engineering

Our senior project involves designing a chassis dynamometer capable of simulating variable loads for the Cal Poly Supermileage Vehicle (SMV) team. The chassis dynamometer we are developing uses an alternator to develop additional resistance that the vehicle will have to overcome while testing. To implement a control system for the variable load, we use an Arduino Nano paired with multiple sensors and drivers. This control system allows the user to select different levels of resistance that correlate with different road grades. We designed a custom Printed Circuit Board (PCB) that will contain all the electrical components needed for the control …

Fiberglass Mat-Roll Carryover, Bryce Youngson, Aaliyah Ramos, Johann Cayaban, Tony Ledesma

Mechanical Engineering

The asphalt shingle is a type of roof shingle that uses asphalt for waterproofing. Its low cost and easy installation make it one of the most common roof covers in North America. General Aniline and Film (GAF) is one of the nation’s largest manufacturers of roofing materials and produces asphalt shingles at their Shafter, California manufacturing facility. To manufacture asphalt shingles, a base material of fiberglass passes through a series of processes that sequentially add asphalt, ceramic-coated mineral granules, and thermoplastic adhesive. The fiberglass base-material arrives at the manufacturing facility in large rolls that workers must periodically splice together in …

Nano Fab Lab 63, Brian K. Deemer, Josh Clemons, Nick Brodine, Delaney Fitzsimmons

Mechanical Engineering

Lawrence Livermore National Laboratories (LLNL) has several steps in the production process for ceramic nanofiber tubes that they would like to improve - electrospinning, cutting, rolling, sealing and heat treating. We undertook the challenge to deliver LLNL with a semi-automated process that efficiently integrates the steps of cutting, rolling, and sealing to save time and improve control over end dimensions. In this document, we discuss the technical background of the manufacturing steps currently followed to create nanofiber tubes, identify which steps are incorporated in our prototype and explain how they will interface with one another, define the design requirements, present …

Danny’S Recumbent Bike Accessibility Device Final Design Report, Joseph J. Lee, Huy Nguyen, Jack Mcatee, John Kulick

Mechanical Engineering

The purpose of this document is to fully define our design solution and explain our manufacturing and testing results. Our project’s goal is to find a way to allow Danny Knutson, a retired Navy pilot and incomplete quadriplegic with limited use of his arms and an impaired sense of balance, to enter and exit his recumbent tricycle without any discomfort for him or his aide. We completed multiple interviews with Danny, patent research, existing product research, and other technical literature research in order to fully understand the problem. We synthesized this information to create a concrete list of customer wants …

Daimscale — 1:14th Tractor-Trailer For Testing Driver Assistance Technology, Christopher Marrale, Jase Sasaki, Devin Bodmer

Mechanical Engineering

Active driver assistance systems are becoming increasingly wide-spread throughout the automotive industry due to their potential for safer roads and decreased costs of transportation, but testing these systems on real trucks can be time consuming, dangerous, and costly. Testing these systems on a small-scale tractor-trailer combination will lead to faster and more efficient development of driver assistance systems and can be used by both engineers and students, leading to a larger field of experienced developers to improve these systems.

Our goal will be to design, manufacture, and build a scale 6x2 model of the tractor portion of a Daimler semi-truck …

Farmbot Trackless Redesign, Cole Thomas, Cailey Kamm, Clayton Alderson, Otto Akerstrom

Industrial and Manufacturing Engineering

For this project the team PLANT3D worked along with Rory Aronson and FarmBot to generate a cheaper more user-friendly design for the FarmBot Genesis 1.3. Working with Rory and FarmBot, we as a team generated a list of design requirements and engineering specifications for the project. These requirements centered around creating a more accessible FarmBot model for the average person to be able to purchase and set up with ease. Much of this required taking the existing system and eliminating the most common problem areas. These were the track system, built using 1.5 meter aluminum extrusions and the complex interchangeable …

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, …

Drawing And Twisting Of Graphene Fibers, Gregory T. Lane, Robert J. Sekerak, Isaias Diaz

Mechanical Engineering

The aim of this project was to develop a more automated process for drawing and twisting of graphene fibers than was currently in place. This was implemented by having two chemical baths with variable speed rollers at either end, and intermediate roller to spool fiber between stages, and a twisting cylinder with integral spool to twist the fiber as it is collected. The goal was to have this first iteration deliver a working prototype, however due to manufacturing delays and timing constraints, that will be missed. A second follow-on project would be able to continue the work presented here and …

Final Design Report: Allergen Mixing Assistant (Ama) Micro-Refrigeration Redesigning, Mitchell Parks, Minwoo (Michael) Suh

Mechanical Engineering

Abstract

Allergen Mixing Assistant (AMA) by Xtract Solutions is a device designed to more “effectively refrigerate, organize, and mix allergenic extracts”. Although Xtract Solutions intended the product to be fully automated, the company has decided against its automation and declared its current design as a minimum viable product whose components are too expensive, difficult to source and complex. Therefore, Cal Poly AMA design team - Mitchell Parks and Minwoo Suh - has decided to replace these expensive components with much more economical alternatives as shown below:

Stirling cooler

→

Thermoelectric (Peltier) cooler

Custom Arduino

Controller Card

→

TEC Thermostat *** …

Cp Ev Dynamics, Steven Montevideo, Ashlie Reott, L. Carter Price

Mechanical Engineering

No abstract provided.

Biomimetic Seal Flipper Test Rig, Gordon D. Belyea, Laura Kawashiri, Dylan Rinker, Kurt Beske

Mechanical Engineering

No abstract provided.

Automated Bearing Press, David Baker, David Brock, Engelbert Diec

Mechanical Engineering

Our group was presented with a challenge to design an automated machine to replace Micro-Vu’s current manual pressing operation. We moved, planned, and scheduled our tasks for the three quarters we will be working on this project by using a Gantt chart. In designing the machine, we generated concepts and used analysis and prototyping to select the most promising ones. Our final design uses a pneumatic press to press the parts, and it includes magazines to hold the parts before pressing, pneumatic actuators to move the parts to and from the pressing location, and a lever to separate the defective …

Low Cost Metal Chip Separator, Alek Linquist, Kale Mckinney, Ryan Jones

Mechanical Engineering

We were tasked by Micro-Vu to design, build, and test a small-scale low-cost metal chip separator to operate on one of their 24/7 mills. The goal of the project was to separate the steel and aluminum chips coming off of the mill’s chip conveyor to end up with a bin of 99% pure aluminum by mass. To accomplish this goal we first brainstormed various possible ideas and performed small scale tests the best ones. After further review we determined the best solution to this problem was a design that involved a cycling magnetic backing that would pull steel out of …