Manufacturing Commons^™

Development And Processing Of Shape Memory Polymer Composites (Smpcs) For Application In Structural Robotics And Robotic Sensors., Kavish Sudan

Electronic Theses and Dissertations

Shape Memory Polymers (SMPs) have attracted significant attention since their introduction in the 1980s due to their remarkable ability to regain their original shape from a temporarily deformed state when exposed to an external stimulus, typically heat. This shape memory effect, driven by thermal transitions such as the glass transition temperature (T_g) or melting temperature (T_m), has made SMPs highly attractive for applications in soft robotics, aerospace, and biomedical devices. However, SMPs face challenges such as limited mechanical strength, thermal stability, and electrical conductivity, which hinder their broader adoption in advanced applications. To address these challenges, …

Synergistic Strategies In Hybrid Mxed Matrix 3d Printing Of Thermoplastics & Thermosets: Design, Manufacturing, And Materials Development., Saleh Akram Khanjar

Electronic Theses and Dissertations

Composite manufacturing and mixed matrix structures have been produced using traditional manufacturing processes for various industrial applications due to their high mechanical properties to material weight and cost ratio. However implementation of composite and mixed matrix manufacturing with advanced manufacturing such as additive manufacturing is limited due to the hardware limitations of current 3d printing technologies and materials available for 3D printing applications. This work has developed and investigated a new hybrid 3D printing manufacturing process utilizing a variety of material systems (thermoplastic – thermoset, thermoplastic – thermoplastic, thermoset – thermoset, thermoplastic – thermoplastic – thermoset). This study developed thermoplastic …

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 …

Modeling, Simulation, And Experimental Testing Of A Single-Legged Hopper, John Anthony Bennett

Master's Theses

Legged robots are well-suited for navigating unstructured terrain due to their ability to perform agile dynamic motions. Building on the efforts of Cal Poly's Legged Robotics Group, this project focuses on achieving stable forward hopping with a single legged robot.

A comprehensive model of leg hopping is formulated, with leg dynamics during flight and stance phases derived using Euler-Lagrange equations. During the stance phase, a spring-mass system models the leg-ground interaction. The touchdown and lift-off conditions are formulated mathematically, and state mappings between phases are determined via momentum conservation. A two-phase hybrid controller is designed, incorporating trajectory planning during flight …

A Survey On Fused Filament Fabrication To Produce Functionally Gradient Materials, Arup Dey, Monsuru Ramoni, Nita Yodo

Manufacturing & Industrial Engineering Faculty Publications

Fused filament fabrication (FFF) is a key extrusion-based additive manufacturing (AM) process for fabricating components from polymers and their composites. Functionally gradient materials (FGMs) exhibit spatially varying properties by modulating chemical compositions, microstructures, and design attributes, offering enhanced performance over homogeneous materials and conventional composites. These materials are pivotal in aerospace, automotive, and medical applications, where the optimization of weight, cost, and functional properties is critical. Conventional FGM manufacturing techniques are hindered by complexity, high costs, and limited precision. AM, particularly FFF, presents a promising alternative for FGM production, though its application is predominantly confined to research settings. This paper …

Examining The Progress In Additive Manufacturing In Supporting Lean, Green And Sustainable Manufacturing: A Systematic Review, Catherine Maware, Rumbidzai Muvunzi, Tinotenda Machingura, Ilesanmi Daniyan

Institute for Sustainable Manufacturing Faculty Publications

The quest for waste reduction and the development of manufacturing processes that meet the economic, social and environmental requirements necessitate this study. Additive manufacturing is an emerging digital technology that can be used to seamlessly develop a product through material deposition in layers. The study aims to investigate the progress made in the development of additive manufacturing to support lean, green and sustainable manufacturing. The study employs a systematic literature review approach, specifically the Preferred Reporting Items for Systematic Reviews and Meta-Analysis (PRISMA). A total of 158 articles identified from different academic databases that detailed empirical, conceptual and theoretical findings …

On The Correlation Between Pre-Processing Workflow And Dimensional Accuracy Of 3d Printed Parts In High-Precision Material Jetting, Karin Chen, Ahmed Elkaseer, Steffen Scholz, Veit Hagenmeyer

Mechanical Engineering

Material Jetting (MJ) is distinguished in the additive manufacturing field for its ability to create accurate multi-material functional objects with features in the range of few micrometers. Analyzing the impact of each step in MJ from virtual design to 3D printed object on the process response is essential for optimizing the technology’s capabilities. The current state-of-the-art reveals a gap in MJ regarding the fundamental understanding of the correlation between the pre-processing workflow and the geometrical and dimensional accuracy. This study aims to bridge this gap by examining factors such as utilization of different CAD software with diverse working principles, part-based …

Large-Scale Research Infrastructure Empowers High-Quality Development Of Private Enterprises: Current Situation, Challenges, And Policy Recommendations, Lingling Zhang, Fuqiang Wang, Mingze Zhang, Zexia Li

Bulletin of Chinese Academy of Sciences (Chinese Version)

Private enterprises have become an important source of innovation in China’s economic development. Large-scale research infrastructure, as a crucial strategic support and innovation element for breaking through key technologies, provides a platform for the innovative development of private enterprises. At present, some large-scale research infrastructures in China, such as the China Spallation Neutron Source and the Shanghai Synchrotron Radiation Facility, have begun actively exploring mechanisms to serve private enterprises. These efforts have helped a number of private companies overcome critical technological bottlenecks and achieve original innovations. Nevertheless, in the current process of opening up large-scale research infrastructures to private enterprises …

Cognitive Manufacturing: Definition And Current Trends, Fadi El Kalach, Ibrahim Yousif, Thorsten Wuest, Amit Sheth, Ramy Harik

Publications

Manufacturing systems have recently witnessed a shift from the widely adopted automated systems seen throughout industry. The evolution of Industry 4.0 or Smart Manufacturing has led to the introduction of more autonomous systems focused on fault tolerant and customized production. These systems are required to utilize multimodal data such as machine status, sensory data, and domain knowledge for complex decision making processes. This level of intelligence can allow manufacturing systems to keep up with the ever-changing markets and intricate supply chain. Current manufacturing lines lack these capabilities and fall short of utilizing all generated data. This paper delves into the …

Spectral Behavior Of Fiber Bragg Gratings During Embedding In 3d-Printed Metal Tensile Coupons And Cyclic Loading, Farid Ahmed, Md Shahriar Forhad, Mahmudul Hasan Porag

Manufacturing & Industrial Engineering Faculty Publications

Additive manufacturing (AM) enables the spatially configurable 3D integration of sensors in metal components to realize smart materials and structures. Outstanding sensing capabilities and size compatibility have made fiber optic sensors excellent candidates for integration in AM components. In this study, fiber Bragg grating (FBG) sensors were embedded in Inconel 718 tensile coupons printed using laser powder bed fusion AM. On-axis (fiber runs through the coupon’s center of axis) and off-axis (fiber is at 5° and 10° to the coupon’s center of axis) sensors were buried in epoxy resin inside narrow channels that run through the coupons. FBGs’ spectral evolutions …

Shape Memory Alloy Capsule Micropump For Drug Delivery Applications, Youssef Mohamed Kotb

Theses and Dissertations

Implantable drug delivery devices have many benefits over traditional drug administration techniques and have attracted a lot of attention in recent years. By delivering the medication directly to the tissue, they enable the use of larger localized concentrations, enhancing the efficacy of the treatment. Passive-release drug delivery systems, one of the various ways to provide medication, are great inventions. However, they cannot dispense the medication on demand since they are nonprogrammable. Therefore, active actuators are more advantageous in delivery applications. Smart material actuators, however, have greatly increased in popularity for manufacturing wearable and implantable micropumps due to their high energy …

How Ai And Digitalization Can Help To Improve Managing Projects In Lean Manufacturing & Supply Chain Environment, Abhijeet Hange

Harrisburg University Dissertations and Theses

This research examines how digitalization and machine learning (ML) revolutionize project management in supply chain and lean manufacturing settings. To improve the efficiency and caliber of their operational procedures, Acuity Brands, Amazon, Walmart, Apple, and other medium-sized businesses—which are at the center of today's competitive markets—are resorting to automation and digitalization. With an emphasis on the fusion of digital and artificial intelligence (AI), the paper explores how successful transformation initiatives are essential to the automation and digitization of manufacturing and distribution hubs. The study uses quantitative methods approach to evaluate the benefits and drawbacks of these technology integrations by integrating …

Comparing Life-Cycle Dynamics Of Li-Ion Batteries (Libs) Clustered By Operating Conditions With Sindy, Kristen L. Hallas, Md Shahriar Forhad, Tamer Oraby, Benjamin Peters, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications

Lithium-ion batteries (LIBs) play a big part in the vision of a net-zero emission economy, yet it is commonly reported that only a small percentage of LIBs are recycled worldwide. An outstanding barrier to making recycling LIBs economical throughout the supply chain pertains to the uncertainty surrounding their remaining useful life (RUL). How do operating conditions impact initial useful life of the battery? We applied sparse identification of nonlinear dynamics method (SINDy) to understand the life-cycle dynamics of LIBs with respect to sensor data observed for current, voltage, internal resistance and temperature. A dataset of 124 commercial lithium iron phosphate/graphite …

Using Sustainable Technique To Recycle Waste Paper In Academic Institutions, Mustafa M. Mansour

Al-Bahir

It has been clearly demonstrated that it would be feasible to consider recycling paper in an academic institution. This can be achieved through combining specific waste paper baskets, a pulping machine and power supplied by a renewable energy source, with an already established local paper making company. The paper making company would be able to gain a subsidy from the government which pays them to actually recycle paper, to counteract the cost of the pulped paper which is 30% more expensive than raw wood pulp. The academic institution would save money on waste disposal and decrease its carbon footprint by …

Exploring The Impact Of Artificial Intelligence On Project Management Across The Manufacturing, Technology, And Construction Industries, Susie Diaz Ferrera

Harrisburg University Dissertations and Theses

This study explores the impact of Artificial Intelligence (AI) on project management across the manufacturing, technology, and construction industries. The research focuses on understanding the benefits, challenges, and long-term implications of AI utilization in these sectors. Key findings indicate that 46% of participants use AI mainly for task automation and enhancing functions like brainstorming and communication, which significantly boosts efficiency and team productivity. Despite these benefits, the research identifies several obstacles, including high initial costs, inadequate training, technical issues, and unclear regulatory guidelines. The study addresses four main questions, revealing that AI not only enhances project management processes but also …

A Screening Life Cycle Analysis Of One-Way And Reusable Crate Designs – Estimating Environmental Impacts Via Lca Software, Nicolas R. Corona

Master's Theses

A comparison analysis conducted via COMPASS life cycle analysis software has indicated that a one-way crate design, rather than a reusable crate design, is in fact the more environmentally friendly packaging system. These results can be interpreted differently, however, as the manufacturer of said crate designs must confirm what impact indicators they would like to reference as environmental goalposts. The conducted analysis provides insight into what the environmental impacts of each packaging system look like as packaging at all three system levels has been identified as a means of reducing environmental impacts globally. As such, the manufacturer of said crate …

Impact Force Helmet Device For Concussion Monitoring, Patrice Mulligan, Karina Mealey, Zack Borthwick, Benjamin Fick

General Engineering

To track head trauma in football, our device is placed inside a football helmet to measure both linear and gyroscopic (rotational) accelerations. These measurements are taken using an ADXL375 linear accelerometer and an LSM6DSOX accelerometer and gyroscope. The data from these sensors is processed and transmitted wirelessly by a SparkFun Thing Plus microcontroller to another SparkFun Thing Plus microcontroller connected to a laptop on the sidelines. Our program on the laptop stores the acceleration impact data into a .csv file for each player. If a likely concussive impact is detected, the program displays a popup warning. Testing results were promising …

Smart Manufacturing For Cal Poly's Ime Curriculum, Grace L. Guarraia, Eric F. Ledesma

Industrial and Manufacturing Engineering

California Polytechnic State University, San Luis Obispo (Cal Poly) takes pride of supporting one of the nation’s strongest undergraduate Industrial and Manufacturing Engineering programs. However, as industry evolves to accommodate advancing computing power, improved manufacturing algorithms, and improved robotics, it is imperative that Cal Poly’s curriculum evolves in parallel. Smart manufacturing is the future of the manufacturing industry, and Cal Poly is searching for the ideal method to teach and integrate Smart Manufacturing into its classes. With its upcoming switch to the semester system, coupled with its “Learn by Doing” motto, the department is at an ideal period for the …

Prototyping Low-Cost Tribometer With Block On Ring Configuration For The Optimization Of Metal-Forming Applications, Immanuel A. Edinbarough, Jaime Taha-Tijerina

Informatics and Engineering Systems Faculty Publications

Applications in the metal-mechanic industry require the analysis and support of tribo-evaluations in their manufacturing processes. Experimentation with various metals and components could be performed under controlled conditions, including the ability to apply testing with a fluid or lubricant media or in dry conditions. The aim of this work is to design and fabricate a working block for a ring tribometer at low cost. Present and future stakeholders will have the ability to analyze material properties in friction, wear, and displacement while saving the university over 500% in costs of an industrial tribometer. The integrity of the machine must adhere …

Enhancing Miter Saw Safety: Challenges And Prospects Of Brake Incorporation With An Automatic Blade Retraction System, Derek Cole

University Honors Theses

Miter saws pose significant safety risks with thousands of injuries reported annually. Despite this risk, they are still used every day as they are a necessity for thousands of workers in the United States and globally. This leaves a demand to make these machines safer to mitigate any potential harm. This research addresses the critical need for an automatic safety system for miter saws, aiming to enhance user safety by retracting and stopping the blade upon skin contact. This analysis identified the primary challenge: The large force generated when braking at high speed on a miter saw blade, translates the …

Focused Led Sintering, Dylan Defazio, Nilav Maulik, Branden Majors, Michael Fontillas

Mechanical Engineering

This report provides a detailed overview of the final design of our light-emitting diode (LED) focusing system. Our system incorporates a converging lens and a specially designed "glass funnel," which acts as a thick fiber optic that narrows the light to a fine point through internal reflection. The glass components of our system are precisely housed in a part made using advanced computer-numeric controlled (CNC) Mill and CNC Lathe manufacturing processes. This ensures high precision and durability of the overall system. Our LED focusing system is designed with a 60-watt stage light. The decision to use a glass funnel as …

Liftwalker, Kai A. De La Cruz, Lexie Caterine, Adam Monroe, Jame Whealan

Mechanical Engineering

The LiftWalker’s purpose is to lift users with degenerative diseases from a seated to standing position and support them as they practice the motion of walking as a form of physical therapy. The current LiftWalker is upward of $5,000 so we redesigned the LiftWalker to be more accessible around the world. This meant using affordable and accessible materials and manufacturing processes. To achieve this, we made our design mostly out of bike parts and off-the-shelf components. When it came to the lift system, we found that to maintain a safe and comfortable design it was best to purchase a trailer …

Barcode Medication Administration (Bmca): 2023-24, Krishan R. Patel, Carlos E. Sosa, Mary Grace Sy

Industrial and Manufacturing Engineering

The Barcode Medication Administration is an important system implemented within a hospital. It is the process in which nurses and other healthcare professionals prescribe and distribute medication to the patients. It aids in organizing which patient got prescribed which medication from which doctor and provides records on who was given care by who. The whole BCMA system is a multi-step process from getting the medication prescribed, to the nurses having to pick up the medication from the medication cabinet, and then having to scan the patient and the medication to finally administer medications.

The current BCMA system implemented at the …

Feasibility And Characterization Of Leak-Tight Single-Track Thin Walls Produced By Laser Powder Bed Fusion In 316l Stainless Steel, Peyton J. Archibald

Master's Theses

This thesis explores the optimization of process parameters for producing single-track thin walls using Laser Powder Bed Fusion (LPBF) additive manufacturing. Using two different coupon designs, the study assesses the feasibility of creating the thinnest possible leak-tight structures within LPBF and evaluating their mechanical properties, including burst pressure and modulus of elasticity under pressure loads. A series of experimental iterations were conducted, varying laser power and laser speed to identify optimal conditions. The findings indicate that a narrow range of process parameters can produce consistently leak-tight thin walls. The results contribute to understanding how to achieve high quality, reliable thin …

Prediction Of Defects In Deep Drawn Rectangular Parts Using Finite Element Analysis (Fea) And Response Surface Methodology (Rsm), Mustafa M. Semman Eng., Mostafa Shazly, Mohamed H. Gadallah, Tamer Adel Mohamed, Abdallah S. Wifi

Mechanical Engineering

Abstract. Deep drawing defects such as thinning and earing present challenges to sheet metal forming industry while designers tend to favour the usage of new materials and production processes. The present work introduces an integrated approach using Design of Experiment, FEA experimentation and RSM to study the effect of deep drawing process parameters and resulting defects associated with sheet metal forming processes such as thinning and earing particularly in deep drawing of non-circular parts. The Design of Experiment (DoE) is used to generate a series of experiments for different process parameters in deep drawn rectangular products which are then simulated …

Cam And Design For Manufacturing: Developing A Project-Based Learning Course, Stephen Pierson

Mechanical Engineering Undergraduate Honors Theses

To effectively serve student career success, mechanical engineering programs must teach students how to account for manufacturing considerations in design. Despite this, manufacturing education is a glaring area of need in current engineering curricula. In fact, basic manufacturing knowledge is one of the only hard skills consistently ranked as one of the greatest weaknesses of mechanical engineering hires in surveys of industrial employers over the last few decades. Without radically changing departmental curriculum to include more emphasis on design-build projects, one solution to combat this is to incubate a lab course in mechanical engineering programs in which undergraduates would practice …

Implementation Of Explainable Ai For Bearing Fault Classification, Mohammad Mundiwala

Honors Scholar Theses

It is difficult to overstate the impact of artificial intelligence (AI) over the past decade. The rapid expansion of machine learning has stimulated a race to deploy AI in all facets of life, one such domain being machine health monitoring. There is no doubt that machine learning excels in prediction accuracy, but oftentimes, these models are cryptic and fail to provide valuable insight into their decisions. This paper presents an overview of a neural network and what it means to learn. Next, two distinct Explainable AI (XAI) techniques will be presented: Gradient Class Activation Mapping and SimplEx . Finally, these …

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 …

Keratin-Based Film: Waste To Bioplastic, Emma Bond

University Honors College

The solution to plastic lies in alternative materials, like bioplastics. One such possibility is keratin-based films. They are made from sources that are already deemed to be waste and that all regions of the world are abundant in. Manufacturing values a one-size-fits-all solution and keratin being plentiful worldwide fulfills that set standard. The films’ properties, which are important to the basic needs of a package, vary with different additives and the type of keratin used. α-keratin and β-keratin have different strengths and are found in nature in different sources. The resource focused on was chicken feathers, which produce more β-keratin …

Design And Fabrication Of A Carbon Fiber Wheel For The Husker Motorsports Club, Benjamin Bashtovoi, Jordan Chapin, Michael Pineda, Caden Lind, Thomas Crum

Honors Program: Senior Projects (Public)

Every year, the Husker Motorsports team participates in a Formula SAE competition that challenges students to design and manufacture a Formula-style vehicle to compete against colleges from around the world. The Husker Motorsports club has sponsored this senior capstone project to improve the vehicle’s performance by reducing unsprung mass. Unsprung mass reduction has numerous benefits on vehicle dynamics, including improved acceleration, handling, and braking. To achieve these performance improvements, the team developed carbon-fiber composite wheels that weigh less than the current wheel solution and provide better rigidity. The team designed and modeled the wheel according to the 2023-2024 competition car …