Manufacturing Commons^™

Mechatronics: Fundamentals, Design, Integration, And Validation, Guoming Zhu

Mechatronics

This textbook is a product of Co-DREAM OER (Collaborative Development of Robotics, Mechatronics, and Advanced Manufacturing Open Educational Resources), an initiative funded by the U.S. Department of Education to develop open educational resource textbooks on robotics, mechatronics, and advanced manufacturing processes. The texts are written for students enrolled in 2-year associate’s, 4-year bachelor’s, and graduate-level courses. This specific text has been created by a team of scholars, students, support staff, and other professionals from across the country. It is intended for mechatronics courses for 4-year bachelor’s and graduate-level programs.

Smart Process Planning For Automated Fiber Placement, Matthew J. Godbold

All Dissertations

Automated Fiber Placement (AFP) is a preeminent manufacturing technology for producing high-performance composite structures, offering precise material placement, reduced waste, and the potential for highly optimized lightweight designs. While AFP has been widely adopted in aerospace applications, its broader use across industries such as automotive, wind energy, maritime, and sporting goods remains limited. A key barrier to wider adoption is the traditional separation of design, manufacturing, and inspection processes, which drives up cost and results in inefficiencies, sub-optimal designs, and limited feedback between lifecycle stages. In current practice, manufacturing is treated as an isolated process, disconnected from early-stage design decisions …

Modernizing Plastics And Composites Manufacturing Using Hybrid Modeling Techniques, Luke Shannon

All Dissertations

Plastics and composites manufacturing encompasses a broad family of processes, including injection molding, resin transfer molding, compression molding, and extrusion, that together account for the vast majority of polymer and composite component production worldwide. These processes are inherently challenging due to the multi-physics nature of polymer processing, the vast possible combinations of resins, reinforcements, and additives, and the strong dependence of final part properties on process history. Among these processes, injection molding is one of the most widely deployed, producing high-volume components across automotive, medical, consumer electronics, and packaging industries. However, accurately monitoring and predicting process behavior in injection molding …

Multi-Criteria Decision-Making For Sustainable Design: Stakeholder Prioritization And Methodological Comparison In Solar And E-Bike Applications, Swagath Madhu Gowda

All Theses

This thesis focuses on using Multi-Criteria Decision-Making (MCDM) methods to support sustainable product design by addressing the trade-offs between environmental, economic, and social goals. The research is presented through two studies that demonstrate how both subjective and objective decision-making approaches can guide sustainability evaluations.

The first study applies the Analytic Hierarchy Process (AHP) to assess residential solar panels by incorporating stakeholder perspectives from sustainability experts, end users, and industry professionals. Using Life Cycle Sustainability Assessment (LCSA) data, this study identifies how different stakeholder groups prioritize sustainability criteria and applies Aggregation of Individual Priorities (AIP) to combine their judgments. A one-at-a-time …

Experimental And Numerical Study On The Influence Of Carbon Fiber Reinforcement On The In-Plane Compressive Properties Of 3d Printed Hexagonal Honeycomb Core Structures, Deon Wallace

All Theses

There is difficulty with numerically replicating the behavior of composite honeycomb core structures numerically due to the trouble of gathering material properties from a hollow structure. Also, complex part geometries and carbon fiber reinforcement strategies can lead to unwanted structural weaknesses and variance in material properties that may not be reflected in numerical analysis when the part is additively manufactured. In this study, edgewise compressive testing is used to characterize the mechanical behavior and performance characteristics of these structures. The experimental results indicate an increase in the Young’s moduli of the honeycomb core structures as carbon fiber concentration increases. However, …

Human Comfort Modeling, Measurement, And Improvement In Human–Robot Collaboration, Yuchen Yan

All Dissertations

A dissertation is proposed to explore human comfort in human-robot collaboration (HRC) through modeling, prediction, and enhancement methodologies. Human comfort is a crucial yet underexplored factor in HRC, directly influencing task efficiency, trust, and overall collaboration effectiveness. Understanding the influential factors, developing computational models, and refining methods to improve human comfort in HRC are essential steps toward advancing the field of collaborative robotics. To address these challenges, multiple studies have been conducted. A series of experimental studies were performed to investigate how robot motion-based parameters affect human comfort in HRC. These studies examined both analytical comfort modeling approaches and physiological …

Ultrafast Laser Surface Structuring For Wettability Control On Copper, Akshay Arvind Nagvenkar

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Wettability is a crucial surface property influencing various phenomena, including heat transfer, cell adhesion, and corrosion. Engineering devices can achieve superior performance by precisely manipulating surface wettability. As a result, extensive research has focused on developing surfaces that exhibit either extreme water attraction (superhydrophilic) or strong water repellency (superhydrophobic). Tailoring surface wettability paves the way for numerous applications, such as drag reduction in marine vessels, controlled drug delivery, efficient water collection, advanced liquid transport systems, oil-water separation, anti-corrosion coatings, friction reduction, and self-cleaning materials. Ultrafast laser surface structuring is a promising approach for engineering multifunctional surfaces, effectively modifying material properties …

Tradespace Exploration With Statistical Modeling Techniques And Immersive Visual Representation In Virtual Environments, Nikhil Raj

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Statistical modeling techniques combined with virtual reality (VR) visualization offer powerful new approaches to tradespace exploration in engineering design. The research presented addresses the challenge of analyzing and communicating insights from complex multidimensional datasets, particularly for autonomous ground vehicle systems.

Beginning with a review of statistical methods—including Principal Component Analysis (PCA), Analysis of Variance (ANOVA), and correlation analysis—the study examines their applications in tradespace exploration. Building on this foundation, three distinct visualization pathways connecting MATLAB data to virtual environments are developed and evaluated: VRML representation, STL conversion, and Blender integration. Each approach is assessed for its ability to maintain data …

An Efficient Computational Frameworks For Design And Analysis Of Metamaterials, Raj Pradip Khawale

All Dissertations

Advancement in additive manufacturing helps in building artificial lattice structures with unique properties that are not available in naturally occurring materials or in continuum structures. Specifically, beam-based lattices are well known for producing lightweight structures with very high strength, auxetic behavior, and energy absorption capabilities. In recent years, numerous research studies have been conducted on generating algorithms and frameworks to obtain unusual properties based on the variation in the cell geometry and material properties. However, the exploration of the full design space is hampered in practice primarily due to restrictions on cell tiling variation. Additionally, the lattices are very intricate, …

Neural Operator And Physics-Informed Deep Learning Approaches For Inverse Design Of Composites And Manufacturing Processes, Minglei Lu

All Dissertations

In this dissertation, artificial intelligence (AI) models are designed and used to accelerate inverse design of composites and manufacturing processes. The critical bottlenecks in machine learning (ML) including data availability, data quality, model generalization and adaptation, interpretability, physical consistency, and the ’black box’ nature of models for the inverse design are addressed. And the proposed AI models are tested under different engineering scenarios. Firstly, a fast deep neural operator (DNO) structure was developed to significantly reduce training time. This model was tested in the context of additive manufacturing, a transformative industrial technology that allows for the creation of materials with …

Predicting The Ductility Of Tungsten Based Bcc Refractory High Entropy Alloys: A Computational Science Driven Study, Akshay Korpe

All Theses

Bcc refractory high entropy alloys (HEAs) are a relatively new category of metallic alloys that promise excellent irradiation resistance and strength retention at high temperatures but exhibit brittle behavior at room temperatures limiting their formability. Understanding the deformation mechanisms and predicting their ductility at room temperature is a topic of interest in contemporary research.

In this work, multiple independent ductility criteria for quantifying the ductility of these HEAs were studied, calculated and compared using Density Functional Theory (DFT) calculations and continuum mechanics frameworks. These ductility parameters were calculated for various W-Ta-Cr-V alloys and the trends were analyzed for each criteria …

Improved Ballistic Impact Resistance Of Nanofibrillar Cellulose Films With Discontinuous Fibrous Bouligand Architecture, Colby Caviness

All Theses

Natural protective materials offer unparalleled solutions for impact-resistant material designs that are simultaneously lightweight, strong, and tough. Particularly, the dactyl club of mantis shrimp features chitin nanofibrils organized in a Bouligand structure, which has been shown to effectively dissipate high-impact energy during powerful strikes. The mollusk shells also achieve excellent mechanical strength, toughness, and impact resistance with a staggered, layer-by-layer structure. Previous studies have shown that hybrid designs, by combining different bioinspired microstructures, can lead to enhanced mechanical strength and energy dissipation capabilities. Nevertheless, it remains unknown whether combining Bouligand and staggered structures in nanofibrillar cellulose (NFC) films, forming a …

Study Of Electrospun Nanocomposite Nanofiber Nonwoven Mats With Precursor Solutions Prepared By Ultrasonic Processing, Stephanie Tussey

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Understanding the complexity of changes in a polymer solution through the addition of nanoparticles and the process used to prepare the solutions is vitally important to obtain desirable characteristics of electrospun nanofibers such as degree of crystallinity, morphological, thermal and mechanical properties. Although there have been significant efforts in this research area, a more in-depth understanding on how nanoparticles can affect the formation of polymeric structures during electrospinning is still needed to ensure overall quality and performance of the nonwoven material. The present study aimed to specifically explore the relationship between solution processing method, nanoparticle volume fraction, and solution properties …

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 …

Temperature Gradient Effect On Solid-Liqid Interface Properties Of Al-Cu Alloy: A Molecular Dynamics Study, Prashant Kumar Jha

All Theses

Aluminum-copper (Al-Cu) alloys are widely used in the aerospace industry due to their favorable strength-to-weight ratio, good fatigue resistance, and corrosion resistance. These properties make Al-Cu alloys an excellent choice for aircraft structural components that require high strength and low weight. Additive manufacturing (AM), also known as 3D printing, has emerged as a promising processing method for Al-Cu alloys in aerospace manufacturing. AM enables the production of lightweight optimized geometries difficult to manufacture through conventional subtractive methods. AM also reduces material waste by only depositing material where needed in the part geometry. The rapid solidification conditions in AM processes motivate …

Femtosecond Laser Shock Peening And The Dynamics Of Femtosecond Laser-Induced Shock Waves, Yuxin Li

All Dissertations

Laser shock peening (LSP) is an important material surface strengthening technique that uses laserinduced shock waves to cause severe plastic deformation near material surfaces. It can significantly improve material properties like hardness, strength, fatigue life, and corrosion resistance and is widely used in industrial sectors such as automotive, aerospace, nuclear, and medical areas. The conventional nanosecond laser shock peening (ns-LSP) has demonstrated effectiveness but faces challenges such as complex setup, low throughput, high energy consumption, and inflexibility for complex geometries. Femtosecond laser shock peening (fs-LSP) offers a promising alternative to overcome these issues, thanks to its ultra-high laser intensity and …

Damage Detection With An Integrated Smart Composite Using A Magnetostriction-Based Nondestructive Evaluation Method: Integrating Machine Learning For Prediction, Christopher Nelon

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The development of composite materials for structural components necessitates methods for evaluating and characterizing their damage states after encountering loading conditions. Laminates fabricated from carbon fiber reinforced polymers (CFRPs) are lightweight alternatives to metallic plates; thus, their usage has increased in performance industries such as aerospace and automotive. Additive manufacturing (AM) has experienced a similar growth as composite material inclusion because of its advantages over traditional manufacturing methods. Fabrication with composite laminates and additive manufacturing, specifically fused filament fabrication (fused deposition modeling), requires material to be placed layer-by-layer. If adjacent plies/layers lose adhesion during fabrication or operational usage, the strength …

Life Cycle Energy Assesment Of Advanced Fiber Reinforced Composite Design And Manufacturing Methodologies, Urjit Lad

All Theses

Automotive industry at large is focused on vehicle light-weighting since a 6%-8% increase in fuel efficiency can be achieved with a 10% reduction in vehicle weight [1]. With the growing demand for cost-effective and sustainable light weighting of automobile structures, interest has increased in the application of fiber reinforced plastic (FRP) composites for use in the Body-in-White (BiW), which can account for up to 40% of the total vehicle weight. Traditional FRP composite manufacturing processes like vacuum assisted resin transfer molding, autoclave consolidation or use of automated fiber placement have been successfully used for marine and aerospace applications. However, these …

The Influence Of Diversity Dimensions On Student’S Collaboration Success: What It Means For Workforce Development In Manufacturing, Oyinkansola Adeite

All Theses

Manufacturing productivity is measured by labor productivity which is the hourly output of the manufacturing economy. The recent reduction in productivity numbers by the United States Bureau of Labor Statistics emphasizes the need for workforce development. With globalization and technological advancements, diversity has emerged as a critical aspect for the workplace. By encompassing dimensions such as education, race, and age, diversity creates a tapestry of unique perspectives and experiences. This study’s aim is to figure out the effect of a diversity dimension on team performance using intelligent systems, and in addition, if extra dimensions of diversity further impact team performance. …

Characterization Of Mechanically Recycled Polylactic Acid (Pla) Filament For 3d-Printing By Evaluating Mechanical, Thermal, And Chemical Properties And Process Performance, Mahsa Shabani Samghabady

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Polylactic acid (PLA) is a biopolymer made from renewable resources such as sugar and corn. PLA filament is a popular material used in Fused Deposition Modeling (FDM) 3D-printing. While this material has many advantages, all the failed parts, support structures, rafts, nozzle tests, and the many prototype iterations during the 3D-printing process contribute to the plastic pollution and release of greenhouse gases. Although PLA is biodegradable, it can take years to degrade in landfills. Instead of throwing away PLA waste and buying new filaments, PLA can be recycled. Amongst the different recycling technologies, mechanical recycling is the most environmentally friendly. …

Multiple Objective Function Optimization And Trade Space Analysis, Yifan Xu

All Theses

Optimization can assist in obtaining the best possible solution to a design problem by varying related variables under given constraints. It can be applied in many practical applications, including engineering, during the design process. The design time can be further reduced by the application of automated optimization methods. Since the required resource and desired benefit can be translated to a function of variables, optimization can be viewed as the process of finding the variable values to reach the function maxima or minima. A Multiple Objective Optimization (MOO) problem is when there is more than one desired function that needs to …

A Benchtop Robotic Automation Approach For Manufacturing Prefilled Syringes, Yehua Zhong

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Automation and robotics have become a staple in the biological manufacturing sector due to their ability to efficiently work without operator inputs, with a high degree of accuracy and repeatability. Industrial robotic arms, in particular, present themselves as valuable tools for biological manufacturing scenarios that require customized solutions due to their ease of programming and flexibility. The traditional hospital-focused healthcare system was organically developed to address acute conditions, however, in recent years, due to the unprecedented occurrence of emergencies happening more frequently, fast and efficient drug production becomes important [17]. This thesis represents the use of a benchtop robot and …

Examining The Different Snap-Through Characteristics Of Bistable Cfrp Composite Laminates, Vishrut Deshpande

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Bistable carbon fiber composites, whose bistability arises from having asymmetric fiber layouts in different layers, have shown immense potential for use in shape morphing and adaptive structure applications. While many studies in this field focus on these composite laminates’ external shapes at the two stable states, their snap-through behavior of shifting from one stable shape to the other remains a critical aspect to be investigated in complete detail. Moreover, symmetric loading conditions have been extensively studied based on the classical lamination theory, but the asymmetric loading conditions received far less attention. Therefore, this study examines an asymmetric, localized point load …

An Experimental Analysis Of Thin Sheet Metal Bending By Ultrafast Laser Peen Forming, Bryce J. Tessmann

All Theses

This study demonstrates the viability of femtosecond laser peen forming for bidirectional sheet metal bending. Ultrafast laser forming is a valuable method thanks to its flexibility, negation of springback, no need for a confining or protective layer, and minimalization of thermal degradation in comparison to other forming processes. However, femtosecond lasers have traditionally been believed to be unsuitable for laser forming in comparison to nanosecond lasers, particularly bidirectional bending, because the induced shock waves were expected to be weak. Conversely, in this study it is elucidated that the femtosecond laser-induced shock waves are extremely strong (several hundred GPa) but the …

Characterization Of Friction Element Welding Using Finite Element Modeling, Ankit Varma

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Friction element welding (FEW) has been advocated as a solution to weld different materials together, with the ability to join high-strength materials for a range of thicknesses with low input energy and a short processing time. This work develops a coupled thermal-mechanical finite element model to better understand the physical mechanisms involved in the process and to predict temperature and material flow during the process. Furthermore, microstructural analysis is performed for the steel layer using a scanning electron microscope and Vickers microhardness tester to understand the variation in its grain structure and hardness. Results from the finite element model and …

Product Lifecycle Management - Application Of Patterning Methods To Gas Turbine Blades And Creation Of Learning Materials, David Procopio

All Theses

To compete in the global marketplace, companies need to embrace virtual design and manufacturing methods. Product Lifecycle Management (PLM) embodies both the workflow processes and tools to bring forth products from conception to design to fabrication to service to decommissioning, and to eventual recycling. In response to the growing demand for engineers and technicians with these critical skills, colleges and universities should introduce these virtual tools through seminars, software workshops, and computer laboratory sessions. Some of the opportunities in the PLM Center at Clemson University include short courses on PLM practices, focused software training sessions, hands-on exploration activities, and research …

Design And Fabrication Of A Polymer Fdm Printer Capable Of Build Parameter Monitoring And In-Sit Geometric Monitoring Via Photogrammetry, Travis Roberts

All Theses

Additive manufacturing, or 3D printing, is a complex process that creates free-form geometric objects by sequentially placing material in a location to construct an object, usually as a layer-by-layer process. One of the most widespread methods is Fused Deposition Modeling (FDM). FDM is used in many of the consumer-grade polymer 3D printers available today. While consumer grade machines are cheap and plentiful, they lack many of the features desired in a machine used for research purposes and are often closed-source platforms. Commercial-grade models are more expensive and are also usually closed-source platforms that do not offer flexibility for modifications often …

Numerical And Experimental Study Of Machining Process Of High Strength Lightweight Materials, Chao Zhang

All Dissertations

No abstract provided.

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

All Theses

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 …