Manufacturing Commons^™

Formula Hybrid Drivetrain Design, Zachary (Zak) Mcfarland, Alex Pruitt, William Domhart

Mechanical Engineering

The Formula Hybrid senior project group was tasked with designing and building a drivetrain system for the Cal Poly Society of Automotive Engineers (SAE) Formula Hybrid (FHSAE) team. FHSAE gave customer requirements for performance and geometry for the drivetrain and the FHSAE rulebook has guidelines regarding safety requirements. The team chose to compete in the electric category of the 2012 FHSAE competition. After getting feedback from previous car performance and researching different powertrain options, the senior project team arrived at three conceptual ideas. Using a quality function deployment method, the senior project team chose the concept where two motors independently …

Recreational Nordic Sit Ski, Mathew Bissonnette, Johnathon Gorski, Kevin Izumiya

Mechanical Engineering

The purpose of this project was to design, build, and test a recreational Nordic sit ski for use by Disabled Sports Eastern Sierra. The goal was to improve adjustability and reduce weight compared to previous sit ski designs. The project was completed by Cal Poly Mechanical Engineering seniors Mathew Bissonnette, Johnathon Gorski, and Kevin Izumiya. Kinesiology seniors Harpreet Saini and Carl Anderson provided discipline support and disability etiquette training.

The project was sponsored by the National Science Foundation Research to Aid Persons with Disabilities (RAPD) grant. The grant was proposed by and awarded to Dr. Brian Self and Dr. James …

Design Of An Independent Star-Clip Organizer (Iso), Christopher Gonzales, Greg Lovasik, Daniel Silveira

Mechanical Engineering

Discussed below is a new concept to sort and deliver star clips for flight deck safety net manufacturing. Multiple methods were generated, along with the necessary research, and were narrowed down to a single concept: the tray-loading preprocess design, named ISO (Independent Star-Clip Organizer). The overall design has been finalized and designed. Due to budget constraints, an actual prototype was not built. However, the design of such a prototype is described by this report, backed with calculations and experimental testing.

Human Powered Helicopter: Rotor Structure, Joseph Ram, Juan Carlos Olvera

Mechanical Engineering

The following report encompasses the Human Powered Helicopter Rotor Team’s conceptual models and ideas based on research and modeling analysis. The following gives an overview of material researched, concept generation, analyzation, manufacturing, and testing for a rotor structure to be installed in a Human Powered Helicopter.

Integrating Courses Through Project Based Learning, Lizabeth Schlemer, Sema E. Alptekin, Karen R. Bangs

Industrial and Manufacturing Engineering

Integrating three courses (one sophomore level, two senior level) through Project Based Learning (PBL) within the Industrial Engineering curriculum at the California Polytechnic State University, San Luis Obispo is presented. Three courses (IME 443 Facilities Planning and Design - senior level; IME 420 Simulation - senior level; and IME 223 Process Improvement Fundamentals - sophomore level) were linked by various mechanisms: Common industry projects, common students in two of the three courses; senior students having access to sophomores in their teams to carry out time consuming tasks such as time studies, and sophomores having access to seniors as team members, …

Effect Of Gold Content On The Microstructural Evolution Of Sac305 Solder Joints Under Isothermal Aging, Mike Powers, Jianbiao Pan, Julie Silk, Patrick Hyland

Industrial and Manufacturing Engineering

Au over Ni on Cu is a widely used printed circuit board (PCB) surface finish, under bump metallization (UBM), and component lead metallization. It is generally accepted that less than 3 wt.% Au in Sn-Pb solder joints inhibits formation of detrimental intermetallic compounds (IMC). However, the critical limit for Au content in Pb-free solder joints is not well established. Three surface-mount package platforms, one with a matte Sn surface finish and the others with Ni/Au finish, were soldered to Ni/Au-finished PCB using Sn-3.0Ag- 0.5Cu (SAC305) solder, in a realistic manufacturing setting. The assembled boards were divided into three groups: one …

Feasibility Analysis For Electrically-Powered Hoverboard, Cameron Chan, Jason Cortez, Jay Lopez

Aerospace Engineering

Composite materials are engineered by combining two or more constituent materials with significantly different physical or chemical properties in such a way that the constituents are still distinguishable, and not fully blended. Due to today’s high rising prices of gasoline and aviation fuel costs, many manufacturers have turned to the use of lightweight composites in their designs due to the advantages of the composite material, which include outstanding strength, excellent durability, high heat resistance, and significant weight reduction that the composite material properties hold. The purpose of this project is to design and construct a composite structure for an electrically-powered …

Lunalight Project: Solar-Rechargeable Led Lantern And Cell Phone Charger, Sean C. Dawson, Michael E. Deagen, Francisco N. Dye, Brian S. Mircheff, Ryan O. Ramelb

Materials Engineering

Today, 1.6 billion people in the world do not have access to grid electricity. Villagers living off the grid in developing nations resort to kerosene lanterns to light their homes. The fumes from burning kerosene are toxic and lead to respiratory illnesses over time. Our sponsor, OneMillionLights, plans to help people to escape poverty by providing them with a clean source of light at night. Children that must work in the fields during the day can use a solar-rechargeable lantern at night to read or study, and street vendors can use the lanterns at night to improve their businesses.

The …

The Morphology Evolution And Voiding Of Solder Joints On Qfn Central Pads With A Ni/Au Finish, Julie Silk, Jianbiao Pan, Mike Powers

Industrial and Manufacturing Engineering

In this paper, we report on a comprehensive study regarding the morphology evolution and voiding of SnAgCu solder joints on the central pad of two different packages – QFN and an Agilent package called TOPS – on PCBs with a Ni/Au surface finish. Samples were isothermally aged at the equivalent of 0, 2, 7 and 14 years service life. Representative solder joints were cross-sectioned and analyzed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) in order to investigate the evolution of the solder joint morphology as a function of Au content and isothermal aging. IMC thickness was …

The Design And Fabrication Of A Microfluidic Reactor For Synthesis Of Cadmium Selenide Quantum Dots Using Silicon And Glass Substrates, Peter Robert Gonsalves

Master's Theses

A microfluidic reactor for synthesizing cadmium selenide (CdSe) quantum dots (QDs) was synthesized out of a silicon wafer and Pyrex glass. Microfabrication techniques were used to etch channels into the silicon wafer. Holes were wet-drilled into the Pyrex glass using a diamond-tip drill bit. The Pyrex wafer was anodically bonded to the etched silicon wafer to enclose the microfluidic reactor. Conditions for anodic bonding were created by exposing the stacked substrates to 300V at ~350oC under 5.46N of force. A syringe containing a room temperature CdSe solution was interfaced to the microfluidic reactor by using Poly (dimethylsiloxane) (PDMS) as an …

Wireless Solar-Powered Thermal Imaging Camera, Andy Bonk, Billy Mcvicker, Jacob Richardson

Mechanical Engineering

Creation of a mounted wireless self-powered thermal imaging camera system.

Ergonomic Lifter, Bejan Brian Banihashemi, Dylan James Schockemoehl, Andrew Ouellet

Mechanical Engineering

No abstract provided.

A Study Of Solder Joint Failure Criteria, Jianbiao Pan, Julie Silk

Industrial and Manufacturing Engineering

One of the challenges in an experimental study of solder joint reliability is to determine when cracks occur in a solder joint or when a solder joint fails. Cracks in a real solder joint are difficult to identify using an X-Ray system. Cross-sectioning and scanning electron microscopy (SEM) is a destructive method. A common non-destructive test method is to monitor resistance increase in a solder joint or a daisy-chain. However, no scientific research has been done in establishing the relationship between the crack area of an interconnection and the change in resistance of the interconnection. This paper proposes a method …

Effect Of Gold Content On The Reliability Of Snagcu Solder Joints, Jianbiao Pan, J. Silk, M. Powers, P. Hyland

Industrial and Manufacturing Engineering

Electroplated Ni/Au over Cu is a popular metallization for printed circuit board finish as well as for component leads, especially wire-bondable high-frequency packages, where the gold thickness requirement for wire bonding is high. The general understanding is that less than 3 wt% of Au is acceptable in SnPb solder joints. However, little is known about the effect of Au content on the reliability of SnAgCu solder joints. The purpose of this paper is to determine the acceptable level of Au in SAC305 solder joints. Three different package platforms with different Au thicknesses were assembled on boards with two different Au …

The Inside-Out Classroom: A Win-Win Strategy For Teaching With Technology, Daniel J. Waldorf, Lizabeth Schlemer

Industrial and Manufacturing Engineering

As costs of higher education soar and many universities face uncertain funding models, institutional pressures have increased to improve instructor efficiency. At the same time, U.S. industry leaders and leading educators have called for improvements in engineering education based on more interactive, hands-on student learning experiences. Although many efforts have been made to take advantage of technology to either improve student learning or to maintain student learning while increasing instructor efficiency, few approaches have been shown to improve both learning and efficiency. A teaching method is proposed to improve student learning and increase student satisfaction while also addressing the instructors’ …

Evolving A Summer Engineering Camp Through Assessment, Katherine Chen, Lizabeth Schlemer, Heather Scott Smith, Teana Fredeen

Industrial and Manufacturing Engineering

EPIC (Engineering Possibilities in College) is a one-week summer program for high school students (entering 9th-12th grades) to learn about engineering and experience hands-on labs in a university atmosphere. It's an opportunity for students to explore the different types of engineering available at many universities. The aim of EPIC is to expand the College of Engineering mission to K-12 students: "To educate students for careers of service, leadership and distinction in engineering or other fields by using a participatory, learn by doing, ‘hands-on’ approach".

Design Projects With Out-Of-Town Companies, Lizabeth Schlemer

Industrial and Manufacturing Engineering

The capstone design class in the industrial engineering department at California Polytechnic State University, San Luis Obispo (Cal Poly) includes projects with companies. The projects are large ambiguous facilities design problems that allow students to incorporate many aspects of the IE curriculum. For the past 15 years students have been participating in these projects with local companies. Over the past several years, companies from out of town (200 miles to the north in Mountain View or 200 miles to the south in Oxnard) have participated. These out of town companies have presented certain logistical issues, but they have proven to …

Pop-A-Wheelie Design Team, Mackenzie Hill, Thuyen Nguyen, Shaun Van't Hul

Mechanical Engineering

The purpose of this report is to illustrate the Pop-a-Wheelie design team’s progression and implementation of a concept in regards to the project sponsored by Break the Barriers (BTB). The Pop-a-Wheelie design team was tasked to design two devices that will be attached onto wheelchairs. The devices should facilitate the independence of user’s ability to pop-a-wheelie and return to an upright position without any assistance. After a list of specifications was agreed upon, the design process initiated. All customer specifications are listed in Objectives section located in Chapter 1: Introduction. A complete engineering specification table can be found in the …

Cal Poly Human Powered Helicopter, Josiah Auer, Eric Behne, Dave Berry, Rebecca Hennings, James Koch, Ian Marquardt, Josiah Mayfield, Sean Miller

Mechanical Engineering

The following report encompasses the Cal Poly Human Powered Helicopter team’s efforts during the 2010-2011 academic year. The intention of this project is to further the knowledge of human powered helicopter design and to validate an ideal configuration through experimental tests and analysis. 

A. Background

The Sikorsky Prize offered by the American Helicopter Society has been the catalyst for many attempts at Human Powered Helicopter (HPH) flight. The requirement to win the prize is a continuous, human powered flight of more than 60 seconds that stays within a 10 meter square box and reaches an altitude greater than 3 meters …

Power Steering Concept, Anthony N. Escobedo, William Ryan Flores, Russell Haverstock

Mechanical Engineering

This senior project was created in conjunction with Edwards Lifesciences. This project was created under an non-disclosure agreement and will not be submitted to any outside sources. The submitted title page will act as proof of completion.

Effect Of Gold Content On The Reliability Of Snagcu Solder Joints, Jianbiao Pan, Julie Silk, Mike Powers, Patrick Hyland

Industrial and Manufacturing Engineering

Electroplated Ni/Au over Cu is a popular metallization for PCB finish as well as for component leads, especially wire-bondable high frequency packages, where the gold thickness requirement for wirebonding is high. The general understanding is that less than 3 wt% of Au is acceptable in SnPb solder joints. However, little is known about the effect of Au content on the reliability of SnAgCu solder joints. The purpose of this study is to determine the acceptable level of Au in SAC305 solder joints. Three different package platforms with different Au thicknesses were assembled on boards with two different Au thicknesses using …

High-Resolution, Non-Contact Angular Measurement System For Psa/Rsa, Ronald D. Sloat

Master's Theses

A non-contact angular measurement system for Pitch Static Attitude (PSA) and Roll Static Attitude (RSA) of hard disk drive sliders is designed and built. Real-time sampling at over 15 KHz is achieved with accuracy of +/- 0.05 degrees over a range of approximately 2-3 degrees. Measuring the PSA and RSA is critical for hard drive manufacturers to control and improve the quality and reliability of hard drives. Although the hard drive industry is able to measure the PSA and RSA at the subassembly level at this time, there is no system available that is able to measure PSA/RSA at the …

Asme Human Powered Vehicle, Benjamin Knaus, Philip Basmadjian, Nick Supat

Mechanical Engineering

Speed Solutions has been contracted to design and build a Human Powered Vehicle (HPV) frame and drivetrain for the Cal Poly HPV club to use in their 2011 race season. This project is being funded by the Cal Poly HPV club and their sponsors. The goal is to design, test and build a bicycle frame that the HPV club can attach to a fairing of their design. Primary design considerations will include speed, weight, cost, rider ergonomics, reliability and ease of repair. This vehicle will be used to compete in ASME’s Human Powered Vehicle Challenge (HPVC) series of races.

Adapted Recumbent Bike, Kurtis Mundell, Dane Tiemeier, Laura Yakuma, Darius Yu

Mechanical Engineering

The adapted recumbent project was to redesign a disabled veteran’s recumbent bicycle.  The main areas of concern were the crank pedal, chain tension, braking and steering system, and ergonomics. Since the customer is an avid biker, this bike will be used often, so the design is based on the ease of repair and replacement.  The crank system was redesigned to a lightweight, adjustable part with chain clearance and high strength. The chain tension was improved by replacing the existing single idler wheel/chain tube system with a dual idler wheel system. The dual idler has a titanium sprocket in one of …

Piedras Blancas Clock Works, Andrew James, Andrew Jupin, Matt Weber

Mechanical Engineering

In 1875, the Piedras Blancas Lighthouse was built to warn ships sailing the California coast of the hazards of the rocky shore. In 1949 a fierce storm damaged the top portion of the lighthouse and the eight ton cast iron and brass assembly had to be replaced by a much lighter piece that still served the purpose of warning oncoming vessels. The former top portion came to rest in downtown Cambria and is still there today, enclosed in a glass room to be observed by visitors and townspeople. Today, the Piedras Blancas Light station is cared for by the Bureau …

Sae Baja: Final Drive Gearbox, Michael Mccausland, Michael Watkins, Ian Masterson, Andrew Sommer

Mechanical Engineering

This paper presents the results of a manual transmission project for SAE Baja. A full engineering process is documented, including problem definition, scheduling, conceptualization, decision theory, synthesis, analysis, manufacturing, and testing. A comparison is made between existing and potential mechanical power train solutions. The final design is analyzed in dynamic simulations, AGMA stress, predicted FFT spectrums, and shifting rod buckling. A number of complicated parts are manufactured through investment casting and direct CNC machining. Issues in the final assembly have prevented the project from being fully realized, recommendations are made for future SAE Baja teams.

Testing The Test: Validity And Reliability Of Senior Exit Exam, Lizabeth Schlemer, Daniel Waldorf

Industrial and Manufacturing Engineering

A senior exit exam is considered an excellent direct measure of student learning for ABET assessment, but the usefulness of the information gathered is related to the validity and reliability of the test itself. The Industrial and Manufacturing Engineering Department at California Polytechnic State University, San Luis Obispo has used a content exam for several years. This paper will discuss test development, administration, and the role it plays in the assessment process. In addition, the test is evaluated using the standard psychometric techniques of reliability and validity. The results of the evaluation are used to refine the test. The importance …

Development And Assessment Of A Pcb Layout And Manufacturong Laboratory Module In Introductory Electric Circuits For Ee And Non-Ee Majors, Albert Liddicoat, Jianbiao Pan, James G. Harris, Gary Perks, Linda Shepherd

Industrial and Manufacturing Engineering

In standard introductory electric circuits laboratories for electrical engineering (EE) majors and non-EE majors, prototype boards are typically used to construct and test electric circuits. Students typically do not learn how to design and manufacture Printed Circuit Boards (PCB) that are commonly used in more sophisticated design projects and other engineering applications. This paper will present the development and assessment of a PCB layout and manufacturing laboratory module that has been used in introductory electric circuits laboratories for EE and non-EE majors. The feasibility of integrating the new PCB layout and manufacturing module into the electric circuit course will be …

Assessing Curriculum Improvement Through Senior Projects, Jianbiao Pan, Albert Liddicoat, James G. Harris, Linda Shepherd

Industrial and Manufacturing Engineering

Senior project and/or capstone design courses are intended to provide a culminating design experience for students and to demonstrate their understanding of engineering knowledge and their ability to apply that knowledge to practical problems. It is expected that the quality and attributes of students’ senior design projects can be used as a good measure of determining how well the curriculum prepares students to engage in engineering design as well as a measure of faculty teaching and student learning. This paper reports the results of a study designed to assess whether the new computer engineering curriculum implemented at Cal Poly over …

Ground Support Equipment For Northrop Grumman Massive Heat Transfer Experiment, Michael A. Manuel, Christopher J. Sparber, Greg A. Trent

Aerospace Engineering

California Polytechnic State University students designed, built, and certified ground support equipment for the Northrop Grumman Massive Heat Transfer Experiment. The Cal Poly design team built the 10000, 20000, and 30000 assemblies to meet Northrop Grumman requirements. The requirements included interface limitations, design load factors, delivery, and testing specifications. The design process consists of requirements generation, conceptual design, preliminary design, design reviews, manufacturing, and certification. The hardware was successfully completed and is used at the Johnson Space and Kennedy Space Center.