Manufacturing Commons^™

Mars Rover Wheels And Drive, Presley S. Sacavitch, Ryan W. Trevena, Dylan A. Mack, Daniel Hudak

Mechanical Engineering

Cal Poly’s Poly1Rover team, advised by Professor Rich Murray, aims to deploy four student-designed mini-Mars rovers, each equipped with a sample-tube retrieval claw, before 2030. However, the wheels of Poly1Rover’s current 6th generation rover are not ready for deployment to Mars, as they do not utilize space-grade materials, are not optimized for manufacturability, and lack sufficient spoke compliance to absorb landing and high-impact loads. This project will be developed by a team of Mechanical Engineering students at California Polytechnic State University, San Luis Obispo (Cal Poly): Daniel Hudak, Dylan Mack, Presley Sacavitch, and Ryan Trevena. Next Intent is providing funding …

Formula Sae Planetary Gearbox Characterization Dynamometer, Trevor Marco Toma, Thomas Welden Pierce, Ethan Liu

Mechanical Engineering

This report outlines a custom hub motor dynamometer requested by the Cal Poly Racing FSAE team. The need for this testing platform is to characterize an existing Formula SAE planetary gearbox for a proposed 4WD powertrain. Hub motors, compact electric machines integrated directly into each outboard wheel, offer significant advantages in efficiency, traction, and chassis packaging compared to conventional RWD drivetrains. By mapping torque capacity, efficiency, lubrication method effectiveness, and fatigue life, the team can validate gearbox design and performance.

This senior project group designed and built a dynamometer according to these specifications which will allow for successful testing to …

Improving The Reliability And Performance Of A Supersonic Indraft Tube Wind Tunnel, Christian J. Kaml

Master's Theses

Access to supersonic testing is increasing in demand, and wind tunnels remain one of the safest and most cost-effective methods for gathering high-speed flow data. Despite being more economical than alternative options, supersonic wind tunnel facilities often require substantial investment to construct, operate, and maintain.

The novel indraft tube tunnel architecture was conceived as a high-speed flow testbed that incorporates features of both Ludwieg tubes and indraft wind tunnels to maintain costs low enough to be accessible even to small universities. This design was first developed and tested in 2018 at California Polytechnic State University, featuring a cost per test …

Me3329 Modular Phonograph Gearbox, Garrett Andrik Leighton, Preston Robert Hupe, Gavin Carter Ebner, Andrew Renato Reyes

Mechanical Engineering

The Mechanical Engineering Department at California Polytechnic State University, San Luis Obispo (Cal Poly), seeks to develop a laboratory tool allowing students to reinforce concepts of gears for Mechanical Systems Design (ME329). Some current laboratories do not provide students with hands-on interaction, and the department lacks equipment and documentation to support a standardized lab. With ME329 expanding from ten to fifteen weeks, there is an opportunity to create a physical gearbox design lab allowing students to reinforce lecture material in engaging ways, while standardizing student learning. This senior project is presented and sponsored by Professor Alan Zhang. It will be …

Mars Mini Rover Sample Retrieval Robotic Claw, Cami Chambers, Ani Lachikian, Alexa Ramirez, Alex Power

Mechanical Engineering

This project involves several key stakeholders, including the Poly1 Rover Club, Professor Rich Murray, and NASA’s Jet Propulsion Laboratory (JPL). The primary objective is to develop an improved robotic claw capable of retrieving sample tubes left by the Perseverance Rover on the Martian surface. In tackling this challenge, the design must account for the harsh Mars climate while integrating cameras and electrical components, durable structure, and a rotational component to the Mini-Rover claw without incorporating an additional motor, sample storage unit, structural aspects or unnecessary weight. The current Mini-Rover consists of a four-degree-of-freedom robotic arm with joints often referred to …

Sensory, Light, And Sound Box, Galilea Andrea Portillo, Hannah Elizabeth Henderson, Marcus Kiyoshi Kanenaga

Mechanical Engineering

The Sensory, Light, and Sound Box senior project outlined an adaptable, mobile sensory environment designed to improve cognitive and visual processing skills for students with Cerebral Visual Impairment (CVI) at the Oceano Education Center. Currently, the market lacks accessible solutions tailored to these non-verbal, low-mobility students, making traditional classrooms overwhelming. This project outlines the modification of an existing static layout into a functional, three-sided wooden over-bed frame that accommodates a standard hospital bed. Our team manufactured a structurally stable verification prototype under a $500 budget, integrating slow-closing outward-hinged walls for safety, dual Bluetooth speakers, and a synchronized LED projector that …

Stakblocks, Micah Satoshi Inoshita, Ava Rose Doerschlag, Cody J. Ellis, Zach M. Lawton, Fernando M. Nalin, Nicholas Humphrey, Aiden Reed Anderson, Sara Maya Suratkal

Mechanical Engineering

Researchers developing sustainable building materials from agricultural waste need a faster way to prototype and evaluate small-scale samples under controlled temperature and pressure before scaling to production. Sponsored by Professor Pete Schwartz of Cal Poly San Luis Obispo, whose work focuses on sustainable technology for developing communities, this project aims to create a prototype testing device for researchers studying agricultural-waste bricks, with the University of Malawi as a potential future testing partner. The final product is intended to inform improved future designs rather than serve as a production-ready device, ultimately supporting the development of affordable, sustainable building materials for communities …

Foldable Transfer Platform, Toby Sagi, Ashton Heiati, Triton Johnson, Zachary Denis

Mechanical Engineering

The report details the design and results of a Hoyer lift to transfer patients between wheelchairs and our sponsor's, Beacon VTC Santa Maria, vans. The lift disassembles into 3 main pieces, allowing the lift to be stored in the back of the van. The lift uses a hydraulic actuator to rotate the boom. We handed over our project to Beacon VTC Santa Maria for use in their facility!

Smart Sleeve, Evan Abalos, Bright Jung, Owen Bowling, Wyatt Eberhart

Mechanical Engineering

Quantifying human arm muscle activity is essential for understanding human movements and helping individuals who suffer from motor or neurological impairments such as stroke or traumatic brain injuries. Today, these individuals, as well as clinicians, researchers, and athletes, face many challenges when using the traditional surface electromyography (sEMG) systems to monitor muscle activities, including complex setup, restricted mobility, discomfort, inconsistent placement of electrodes, and lack of accuracy. Therefore, a comfortable EMG sleeve device that accurately measures arm movement without interfering with daily tasks is needed, which the team will be designing, manufacturing, and testing as their senior project. In addition, …

Process Improvement For Thermal Barrier Coating Masking Applications, Katherine Meezan, Aiden Senn, Saksham Giri, Katelyn Perez

Mechanical Engineering

Solar Turbines, a gas turbine manufacturer, needs a more efficient method to prevent the application of a thermal barrier coating (TBC) to select areas of their combustion liners during manufacturing. Currently, the process is labor, material, and time intensive: reusable masking tools should increase the efficiency of the TBC process.

This project is sponsored in full by Solar Turbines, and is under the guidance and administration of three Solar Turbines engineers: Chris Noone, Rick Rogers, and Carson Roff. The project is mentored by Cal Poly senior design Coach, Rick Lasko. This project will be completed by a team of four …

Simulation Of Powder Spreading For Metal Additive Manufacturing, Florence Duff

Master's Theses

The powder recoating process for Laser Powder Bed Fusion requires iterative experimentation to develop the correct process parameters that will result in high quality parts. There currently lacks good spread quality metrics and models for optimizing spread quality. A machine that simulates the powder spreading process was built to streamline the process of selecting process parameters for specific types of powders without having to operate the full laser system. The parameters investigated were the layer thickness and spreading speed. The response variables were metrics developed to assess spread quality: the percentage of the build plate covered by powder and the …

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 …

Bonderson Workbench, Han Xu, Aidan Robleto, Sean Murphy, Victor Duran

Mechanical Engineering

This project redesigns the existing creative workbenches in Cal Poly's Bonderson High Bay to improve mobility and functionality for students and staff in the Mechanical Engineering Department.

Fsae Bespoke Brake Calipers For Hub Motor Architecture, Connor William Vaughan, Liam Upton Walsh, Bradley Brian Kern

Mechanical Engineering

Brakes are the most critical safety system on any performance vehicle, and as Cal Poly Racing transitions their Formula SAE car from a single rear motor to a four-in-wheel motor setup with regenerative braking, the team identified an opportunity to develop a bespoke brake caliper tailored to their specific needs. This document outlines the research, design, manufacturing, and validation of custom front brake calipers designed to improve upon commercial motorcycle calipers in key areas such as serviceability, mounting rigidity, thermal behavior, mass, and hub motor integration. The resulting design is a two-piece, four-piston, radially-mounted aluminum caliper featuring titanium pistons, toolless …

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.

Design And Development Of A 12-Degree-Of-Freedom Quadruped Robot, Kai De La Cruz

Master's Theses

This thesis presents the design, analysis, and experimental validation of a 12-degree-of-freedom (DOF) quadruped robot developed as a research platform for legged locomotion and control. The system builds upon the Cal Poly Legged Robotics Group’s prior 8-DOF quadruped, addressing key limitations in manipulability, load distribution, and mechanical robustness by introducing a 3-DOF leg architecture.

The mechanical design emphasizes lightweight construction, structural integrity, and modularity to support future research extensions. Static and dynamic loading models were developed to inform component sizing and material selection. A carbon-fiber chassis and redesigned leg assemblies were fabricated and validated through finite element analysis and physical …

Origami-Inspired Pneumatic Soft Robotic Gripper, Conor J. Schott

Master's Theses

This thesis presents the design and evaluation of a vacuum-actuated, origami-based soft robotic gripper. A custom Sea Urchin crease pattern forms a lightweight folding skeleton that collapses radially under vacuum. The system emphasizes low cost and accessibility through laser cutting, 3D printing, and silicone molding. The Sea Urchin geometry was selected after digital and physical screening of candidate crease patterns for smooth folding, low strain concentration, and uniform inward motion. The folding skeleton is laser cut from 4 mil drafting film and folded into a compliant core. Four membrane configurations were developed: an origami gripper with a 36-inch balloon (Design …

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 …

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 …

In-Situ Defect Detection In Selective Laser Melting Using Convolutional Neural Networks, Ethan Gaigalas

Master's Theses

This thesis develops and trains a convolutional neural network (CNN) to classify defects in metal parts produced by selective laser melting (SLM) using acoustic emission (AE) data. The model successfully identified porosity and standard build layers with high accuracy but consistently struggled to classify lack of fusion (LOF) defects, regardless of input type, normalization, or class count. These results suggest that while AE signals contain distinguishable features for certain defect types, LOF signals may be too subtle or inconsistent for reliable detection. The study addresses the ongoing challenge of in-situ quality monitoring in metal additive manufacturing, where defects like cracks, …

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 …

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 …

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 …

Llnl Raft Flash Pole Redesign, Jack Stangel, Evan Wolfson, Jake Borden, Alexander Meeter

Mechanical Engineering

During research exercises in the ocean, Lawrence Livermore deploys a fleet of rafts outfitted with flash modules affixed to tall poles (in tandem called flash poles) that flash while a photo is taken to act as datums for data collection. The current flash pole design that the LIDSS (Lawrence Livermore Independent Diagnostic Scoring System) team uses is too short to be visible in high seas, not mechanically suited to be made taller, too susceptible to the elements and blunt impact and too difficult to service. We aim to solve these issues.

Micro Mobile Home R3, Roha Y. Ali, Yuka M. Iwashita, Luke C. Douglas, Joshua Q. Le

Mechanical Engineering

Homelessness is an ever-growing issue all around the world. In 2023, over 250,000 or ~40% of all people experiencing homelessness did not have access to shelter spaces in the U.S. [1]. All people have the right to a place where they are safe from violence, crime, and the constant fear that they will be forced out.

Both homeless people and outdoor enthusiasts need a new way to keep themselves and their belongings safe when living outdoors, since existing products do not offer adequate security, portability, or versatility.

2024-2025 Cal Poly Fluid Power Vehicle Competition Team, Jaskaran Singh Hothi, Justin Menzie Lesko, Tristan Kai Crawford, Lucas Rupert Erickson, Diego Velazquez

Mechanical Engineering

The Fluid Power Vehicle Challenge (FPVC) provides an avenue for the exploration of fluid-powered transportation, adhering to regulations set by the National Fluid Power Association (NFPA). This document serves as a roadmap for our team’s research, design, and manufacturing of a vehicle for participation in the FPVC. The team’s journey began with extensive background research, encompassing stakeholder engagement, analysis of existing solutions, and education on fluid power fundamentals. From this information, we decided to focus on enhancing mechatronics systems, improving the transmission, optimizing the mounting, adding a pneumatic element, and improving the efficiency of the hydraulic system of the vehicle …

Design Principles For Robotic-Controlled 3d Printing Of Soft Tissue-Mimicking Materials, Karina Mealey

Master's Theses

Geometrically and physically accurate 3D models are emerging as essential tools for surgeons in pre-operative planning and training, but current methods of producing these models are not sufficient. Existing solutions have downsides such as high costs, long and tedious production times, high complexity resulting in a lack of scalability, or an inability to meet material requirements for accurately simulating human tissue.

The objective of this work is to develop principles for a low-cost, easy-to-use 3D printing system capable of prototyping with soft tissue-mimicking materials. To pursue this goal, a MyCobot280 robot arm was used as the mechanism to explore the …