Manufacturing Commons^™

Agar-Natural Polymer Composites For Packaging Applications, Alaa Alnatsheh

Discovery Day - Daytona Beach

Global plastic production reached 359 million metric tons in 2018, with packaging accounting for about 31% of total use and expected to continue increasing toward 2060. Recycling remains limited, with approximately 66% of recyclable packaging in the United States not being recycled. These challenges have increased interest in biodegradable materials derived from renewable sources. Agar, a polysaccharide extracted from red seaweed, has strong film-forming ability but shows limitations such as low mechanical strength and high water sensitivity. This study investigates agar-based bioplastic films using three formulation approaches: agar-starch (binary), agar-starch-chitosan (ternary), and agar with nanocellulose (nano-enhanced). Films were prepared using …

Innovative Controls For Combustible Particulate Dust In Industrial Refineries, Sadie Dickman

Discovery Day - Daytona Beach

This project entails an extensive analysis of the occupational combustible dust hazard that exists in industrial refineries, including food processing, manufacturing, and metalworking facilities. Based on prior accidents like the 2008 Imperial Sugar and 2017 Didion Milling explosions, combustible dust causes fire and explosion risks that can result in damages, injuries, and fatalities. Through comparison of OSHA regulations, NFPA standards, and accident data, a lack of effective standards regarding training, audits, ventilation, fire prevention, and adequate housekeeping measures were highlighted to be an existing safety gap. The purpose of this study is to propose administrative controls to mandate companies to …

Experimental Manufacturing Optimization Of 3d-Printed Ducted Fans, Stanlie Cerda-Cruz

Discovery Day - Daytona Beach

This study aims to assess the efficiency gains, feasibility, and practicality of 3D printing fan and ducts with pre and post processing techniques. With the rapid expansion of MAV use; labs, students, hobbyists, can benefit from manufacturing Electric Ducted Fans (EDFs), both fans and ducts, in-house rather than purchasing traditional propellers. There are several advantages of utilizing EDFs, as they can minimize wing tip vortices, reduce wake contraction, and induce a duct lip Coanda effect which all lead to an increased system efficiency. However, EDF implementation in MAV's remain largely unexplored due to the difficulty of development and the production …

Additive Manufacturing Of Metals: Mechanical Properties And Their Implications, Sean Chih

Discovery Day - Daytona Beach

Additive manufacturing of metals is a relatively new and groundbreaking approach to manufacturing high-performance components. However, variability in mechanical properties from the process creates a barrier before this manufacturing technique can be widely applied. Understanding when and where to use this manufacturing is also important to create components with efficiency and without harmful defects. The objective of this research is to evaluate the effects of build orientation, printing parameters, internal defects, thermal history, and residual stresses, post-processing heat treatments, and fatigue behavior on additively manufactured components. Literature-based research is conducted on commonly used metals for additive manufacturing, such as stainless …

A Feedback Loop Control To Automate Cold Atmospheric Pressure Plasma Based Additive Manufacturing, Arineh Shahbazi

Discovery Day - Daytona Beach

Currently, nanoparticle annealing based additive manufacturing process requires high temperatures, making them unsuitable for a broad range of applications. By lowering the temperature and developing a process to use Cold Atmospheric Pressure Plasma (CAPP) for annealing, many more doors are opened to a wide range of materials, films, and environments for space, communication, and microelectronics. CAPP-based additive manufacturing technology is continually evolving, making projects like nanoparticle annealing more feasible. In this work, we designed a CAPP jet printer assembly consisting of a 0.25-inch outer diameter glass tube connected to a 3D printing nozzle. The flow of Argon gas in the …

Automation And Robotics In Timber Construction Prefabrication, Jason Grabowski, Anish Mandyam, Samuel Mcaraw, Jacob Jander

Discovery Day - Daytona Beach

Robotics and automation have varying degrees of utilization across the construction prefabrication industry. The timber prefabrication industry is uniquely positioned for the implementation of robotics and automation due to the environment being more controlled than most of the construction industry. Current developments are influenced by the evolution of "Construction 4.0/5.0," where the integration of digital technologies and robotics is transforming timber prefabrication from traditional subtractive CNC machining into a highly precise, additive, and collaborative process. The purpose of this project is to conduct a systematic literature review of the state of-the-art and near-future developments of automation and robotics in timber …

Influence Of Infill Geometry On The Vibrational Behavior Of 3d-Printed Cantilever Beams, Owen Maute

Discovery Day - Daytona Beach

Vibration and damping are important considerations in many engineering structures, especially as additive manufacturing becomes more widely used in functional mechanical components. This project investigates how the internal structure of 3D-printed parts affects their vibrational behavior. A series of cantilever beams with identical outer dimensions will be designed and manufactured using a 3D printer with PLA filament, since PLA is one of the most commonly used materials in consumer and prototyping-level additive manufacturing. The study will examine five different infill patterns at three different infill densities, producing multiple beam configurations that vary only in their internal geometry. In addition to …

Direct Ink Writing Of Functional Fiber/Granular Composites, Zhuoyuan Yang

Doctoral Dissertations and Master's Theses

Direct ink writing provides a versatile manufacturing route for fabricating functional fiber and granular composites with controlled architecture, tunable interfaces, and customized material distributions. Fiber reinforced composites offer high stiffness, strength, fatigue resistance, and functional anisotropy, while granular composites provide scalable access to particle based structures with high material efficiency and broad resource compatibility. However, the additive manufacturing of these composite systems remains challenging. For fiber based composites, precise control of fiber placement, matrix impregnation, interfacial bonding, and freestanding deposition is difficult to achieve during printing. For granular composites, stable particle flow, controllable packing, binder infiltration, and shape retention are …

Mitigation Of The Environmental Impacts Of Lithium Extraction And Lithium Battery Manufacturing, Dominick R. Strollo

Sustainability Conference

Lithium extraction and the production methods utilized for lithium-ion batteries can have a large impact on the areas directly surrounding them, and if not mitigated properly, the rest of the world as well. For these batteries to be produced, lithium must be mined and refined from sources all around the world. The main concern of lithium mines is their impact on the water cycle and the surrounding water tables due to the heavy metals involved in the process and the sheer amount of water required. Production of the batteries themselves using the lithium slurry is far less impactful on the …

Modeling, Control, And Hardware Development Of A Thrust-Vector Coaxial Uav, Andrew North

Doctoral Dissertations and Master's Theses

This thesis introduces a unique thrust vector coaxial unmanned aerial vehicle (UAV) configuration and presents a comprehensive investigation encompassing dynamics modeling, hardware design, and controller development. Using the Newton-Euler method, a dynamic model for the UAV is derived to gain in-depth insights into its fundamental flight characteristics. A simple thrust model is formulated and modified by comparing it with data obtained from vehicle testing. The feasibility of manufacturing such a vehicle is assessed through the development of a hardware prototype. Finally, a linear state feedback controller is designed and evaluated using the non-linear dynamics model. The results demonstrate successful validation …

Biomass Characterization And Insulation Optimization Studies, Hussein Awad Kurdi Saad

Doctoral Dissertations and Master's Theses

This study indicates how biomass materials can be effectively used as naturally sustainable alternatives to insulation materials. Barley grains and oak leaves, straw, and jute are collected, and crushed into powders/ chopped pieces. The physical characteristics are measured to characterize each powder. The biomass powder reinforced composites are manufactured in varying weight ratios. The density and thermal conductivity of composite materials are measured. The properties of composites compared to those of commercial insulation materials are found to be close to them. Furthermore, genetic algorithms (GA) can be used to achieve multi-objective optimization entailing maximizing insulation (minimizing heat transfer) and simultaneously …

An Economical Method For Securely Disintegrating Solid-State Drives Using Blenders, Brandon J. Hopkins Phd, Kevin A. Riggle

Journal of Digital Forensics, Security and Law

Pulverizing solid-state drives (SSDs) down to particles no larger than 2 mm is required by the United States National Security Agency (NSA) to ensure the highest level of data security, but commercial disintegrators that achieve this standard are large, heavy, costly, and often difficult to access globally. Here, we present a portable, inexpensive, and accessible method of pulverizing SSDs using a household blender and other readily available materials. We verify this approach by pulverizing SSDs with a variety of household blenders for fixed periods of time and sieve the resulting powder to ensure appropriate particle size. Among the 6 household …

Environmental Advantages In Additive Manufacturing, Analise Walter, Cheryl Marcham

Publications

Additive Manufacturing (AM) is a technology that uses a variety of methods to ultimately apply layers of material and create products (Ford & Despeisse, 2016; Ford, Mortara & Minshall, 2016). Although there has been an expansion in recent technology, AM has been used in manufacturing for a few decades (Ford, Mortara, et al., 2016). Since the late 1980s, AM has grown from simple product designs, with a focus on prototyping and customization, to modern times with billions of dollars in revenue and large-scale production of consumer and industrial products (Cotteleer, 2014). Forecasts showed a near $10 billion market by 2020, …

3d Textile Preforms And Composites For Aircraft Strcutures: A Review, Abbasali Saboktakin

International Journal of Aviation, Aeronautics, and Aerospace

Over the last decades, the development of 3D textile composites has been driven the structures developed to overcome disadvantages of 2D laminates such as the needs of reducing fabrication cost, increasing through-thickness mechanical properties, and improving impact damage tolerance. 3D woven, stitched, knitted and braided preforms have been used as composites reinforcement for these types of composites. In this paper, advantages and disadvantages of each of them have been comprehensively discussed. The fabric architects and their specification in particular stitched preforms and their deformation mode for aerospace applications have been reviewed. Exact insight into various types of damage in textile …

Manufacturing Process Simulation – On Its Way To Industrial Application, Dennis Otten, Tobias A. Weber, Jan-Christoph Arent

International Journal of Aviation, Aeronautics, and Aerospace

Manufacturing process simulation (MPS) has become more and more important for aviation and the automobile industry. A highly competitive market requires the use of high performance metals and composite materials in combination with reduced manufacturing cost and time as well as a minimization of the time to market for a new product. However, the use of such materials is expensive and requires sophisticated manufacturing processes. An experience based process and tooling design followed by a lengthy trial-and-error optimization is just not contemporary anymore. Instead, a tooling design process aided by simulation is used more often. This paper provides an overview …

Damage Characterization Of Aircraft Fuselage Using Vibrothermography Technique-Review And Analysis, Abbasali Saboktakin

International Journal of Aviation, Aeronautics, and Aerospace

Vibrothermogrphy is a promising non-destructive technique that uses ultrasonic elastic waves to detect damages and is typically applied in the aerospace and automotive industries. This technique allows for defect selective imaging using thermal waves that are generated by ultrasound waves. In this paper, vibrothermography technique was applied to the aircraft fuselage to detect its damage. The influence of the damage on the temperature distribution at the damage region on the aluminum was investigated by finite element technique. Comprehensive understanding in edge crack in fuselage heating caused by local friction between crack surfaces was obtained.

Advances In Composite Manufacturing Of Helicopter Parts, Tobias A. Weber, Hans-Joachim K. Ruff-Stahl

International Journal of Aviation, Aeronautics, and Aerospace

This study investigates and compares different methods for improving standard autoclave composite manufacturing in order to find suitable approaches to a more efficient composite production. The goal is not only a reduction in manufacturing times and costs but also quality enhancement. Improved part quality while decreasing costs enables a manufacturer of composite parts to expand its market share, especially in the helicopter market, which has been constantly shrinking over the last two years. Various approaches such as improved tooling technology, the use of automated systems for lamination as well as outsourcing are examined to provide an overview of possible advancements …

Trustworthiness Requirements For Manufacturing Cyber-Physical Systems, Radu F. Babiceanu, Remzi Seker

Publications

Distributed manufacturing operations include cyber-physical systems vulnerable to cyber-attacks. Long time not considered a priority, cybersecurity jumped to the forefront of manufacturing concerns due to the need to network together legacy, newer equipment, and entire operation centers. This paper proposes trustworthiness solutions for integrated manufacturing physical-cyber worlds, where trustworthiness is defined to complement system dependability requirements with cybersecurity requirements, such that the resulting manufacturing cyber-physical system delivers services that can justifiably be trusted. Acknowledging the inevitability of cyber-attacks, the paper models the cybersecurity component using the resilient systems framework, where system resilience is viewed as preservation of a required state …

Project Daedalus: An Additive Manufacturing Vending Machine, Paul A. Galarnyk, Roxanna Stein, Priscilla Mcdonald, Sky Comarsh White, Matthew Caixeiro, Alexander Seifans, Chris Hays, Benjamin Sallick, Katherine Mcbrayer, Skyler Singleton, Scott Wt Kent

Student Works

The project was a research endeavor focused on designing and building a vending machine for 3D-printed parts. It also had the secondary objective of catalyzing leadership qualities among its membership by emphasizing individual responsibility and forward thinking. The project began in the spring of 2015, when the topic of autonomous 3D-printing was chosen, funding was secured, and the majority of the leadership was brought on. Over the summer and into the fall semester the team developed project requirements and infrastructure, and gathered members from the parent organization. By December of 2015 most of the machine design had been completed, and …

The Design For Manufacturing And Assembly Analysis And Redesign Of An Aircraft Refueling Door Hinge Utilizing Additive Manufacturing, Kurt A. Schwarz

Doctoral Dissertations and Master's Theses

In this thesis, an aircraft door hinge assembly provided by Gulfstream Aerospace was analyzed following an established process called DFMA. The hinge was then redesigned to be additively manufactured, which is uncommon currently in industry for load bearing components. It was shown that the Design for Manufacturing (DFM) guidelines were inadequate when applied to the new technology of additive manufacturing (AM). This was primarily due to AM's unique and unprecedented manufacturing capabilities.

A conservative redesign approach was followed due to a limitation in current AM material properties and time available for analysis. Despite this, a significant improvement in weight reduction …

Investigation Of Traditional And Alternate Living Hinge Designs For Fused Deposition Modeling Additive Manufacturing Process, Cassandra Sue Gribbins

Doctoral Dissertations and Master's Theses

A manuscript-style thesis composed of three studies covered the application of living hinge designs in the additive manufacturing process of fused deposition modeling. Initial research included comparing numerical and analytical linear analyses on a traditional living hinge design. The second research consisted of tensile testing for the material properties of the Acrylonitrile Butadiene Styrene (ABS) used in fused deposition modeling (FDM) process by the MakerBot 2X as well as adjusting the traditional design to be printed. The third study explored alternate living hinge designs that utilize the geometric freedom provided by additive manufacturing to more evenly distribute stress across the …

Running With The Pack: Jit & Automation For Small Manufacturers, Thomas E. Phillips, John R. Ledgerwood

Publications

While both just in time (JIT) concepts and automation programs have been widely implemented and highly successful in large manufacturing companies, many smaller manufacturing companies have wondered whether it would be economically feasible to utilize these same techniques and derive these same benefits. When JIT is adopted by small manufacturers, it provides them with advantages over traditional manufacturing systems, such as lower cost, quality improvements, higher productivity, and less working capital tied up in inventory. Small US manufacturers must understand the basic principles and philosophy of JIT and update their production equipment if they are to be competitive in today's …