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 …

Manufacturing Of A Wooden Tortilla Press: Idea To Production, Glenn H. Walker

Honors Theses

The purpose of this thesis is to document the design, development, and manufacturing of a wooden tortilla press completed as a capstone project through the Center for Manufacturing Excellence (CME). The project follows a structured product development process that began with problem definition and concept development, progressed through design, prototyping, and jig fabrication, and culminated in a full production run on the CME shop floor. A multidisciplinary team, including engineers, a marketer, and an accountant, collaborated throughout the project to support both technical development and manufacturing execution. Project planning and scheduling were established early and maintained throughout the project to …

Design And Development Of A Manufacturing Process For A Raised Planter Box, Weslyn Mcmurrin, Larson Looney, Haneef Adebisi, Rachel Hipskind, Carolyn Hale

Honors Theses

This report presents the design and manufacturing process of a raised garden bed box with an integrated irrigation system. The goal of this project was to replicate a manufacturing environment in the creation of a durable, ergonomic, and cost-effective product. The project began in Spring 2025 with initial market and financial research to determine design requirements and materials for prototype development and continued through the end of the Fall 2025 semester with a small-scale production run and team presentation. Following our market and financial research, multiple design concepts were evaluated and refined through the use of computer-aided design and prototype …

Manufacturing Process Of A Wooden Tortilla Press: Idea To Production, Colleen Nolan, Ben Bird, Olivia Marque, Emma Palmer, Hayden Walker

Honors Theses

The purpose of this thesis is to document the design, development, and manufacturing of a wooden tortilla press completed as a capstone project through the Center for Manufacturing Excellence (CME). The project follows a structured product development process that began with problem definition and concept development, progressed through design, prototyping, and jig fabrication, and culminated in a full production run on the CME shop floor. A multidisciplinary team, including engineers, a marketer, and an accountant, collaborated throughout the project to support both technical development and manufacturing execution. Project planning and scheduling were established early and maintained throughout the project to …

The Design And Manufacturing Process Of The Concealed Shelf, Joshua Harvel

Honors Theses

The Haley Barbour Center for Manufacturing Excellence (CME) at the University of Mississippi challenges students to manufacture a product and put forth a balanced manufacturing line in a senior capstone project. The chosen product was a concealed shelf, or a shelf with a hidden compartment. The team aimed to design a product, formulate a project plan, analyze the market, conduct financial analysis, develop a prototype, establish a manufacturing process, and demonstrate that process in two production runs. The team used tools such as Computer Aided Design (CAD), market surveys, jig creation, and line balancing to accomplish these tasks. After two …

Development Of A Putting Green Manufacturing Process, Tabitha R. Webster

Honors Theses

Our Capstone project investigates the end to end design, development, and production of a 6‑foot long portable putting green marketed for individuals seeking a high quality, competitively priced golf product for home or office use. The capstone project examines the full lifecycle of product creation applying manufacturing principles learned through the center of manufacturing’s coursework. From the initial concept through engineering design, market research, prototyping, manufacturing optimization, and final production the project emphasizes cross‑functional collaboration across engineering, business, and accountancy majors. Methods used to gather data included marketing surveys, CAD drawings, time studies during production runs, value stream mapping, and …

The Design And Manufacturing Process Of The Concealed Shelf, Clarence A. Matthews Iv

Honors Theses

The Haley Barbour Center for Manufacturing Excellence (CME) at the University of Mississippi challenges students to manufacture a product and put forth a balanced manufacturing line in a senior capstone project. The chosen product was a concealed shelf, or a shelf with a hidden compartment. The team aimed to design a product, formulate a project plan, analyze the market, conduct financial analysis, develop a prototype, establish a manufacturing process, and demonstrate that process in two production runs. The team used tools such as Computer Aided Design (CAD), market surveys, jig creation, and line balancing to accomplish these tasks. After two …

Manufacturing Processes Of A Wooden Tortilla Press: Idea To Production, Emma J. Palmer, Glenn Walker, Colleen Nolan, Olivia Marque, Benjamin Bird

Honors Theses

This thesis follows the Manufacturing Process of a Wooden Tortilla Press from idea to production following lean manufacturing processes and producing a valuable, and profitable product.

Development Of A Putting Green Manufacturing Process, Jose Andres Cepeda Santiago

Honors Theses

Our Capstone project investigates the end-to-end design, development, and production of a 6‑foot long portable putting green marketed for individuals seeking a high quality, competitively priced golf product for home or office use. The capstone project examines the full lifecycle of product creation applying manufacturing principles learned through the center of manufacturing’s coursework. From the initial concept through engineering design, market research, prototyping, manufacturing optimization, and final production the project emphasizes cross‑functional collaboration across engineering, business, and accountancy majors. Methods used to gather data included marketing surveys, CAD drawings, time studies during production runs, value stream mapping, and controlled documentation …

Development Of A Putting Green Manufacturing Process, Avalon R. Madden

Honors Theses

Our Capstone project investigates the end to end design, development, and production of a 6‑foot long portable putting green marketed for individuals seeking a high quality, competitively priced golf product for home or office use. The capstone project examines the full lifecycle of product creation applying manufacturing principles learned through the center of manufacturing’s coursework. From the initial concept through engineering design, market research, prototyping, manufacturing optimization, and final production the project emphasizes cross‑functional collaboration across engineering, business, and accountancy majors. Methods used to gather data included marketing surveys, CAD drawings, time studies during production runs, value stream mapping, and …

The Design And Manufacturing Process Of The Concealed Shelf, Emma R. Freeman

Honors Theses

The Haley Barbour Center for Manufacturing Excellence (CME) at the University of Mississippi challenges students to manufacture a product and put forth a balanced manufacturing line in a senior capstone project. The chosen product was a concealed shelf, or a shelf with a hidden compartment. The team aimed to design a product, formulate a project plan, analyze the market, conduct financial analysis, develop a prototype, establish a manufacturing process, and demonstrate that process in two production runs. The team used tools such as Computer Aided Design (CAD), market surveys, jig creation, and line balancing to accomplish these tasks. After two …

Lunar Manufacturing Systems And The Role Of Additive Recycling Technologies, Camille A. Newman

Honors Theses

Renewed international interest in sustained lunar exploration has created a growing demand for technologies to support long-duration space exploration. Part of the recent Artemis missions and the Moon to Mars initiative is to improve key mission capabilities and fill critical gaps necessary to sustain lunar habitation. Waste management, recycling systems, and manufacturing systems have been identified as critical technologies that need further development before a sustained mission is possible. This thesis explores the feasibility of an additive manufacturing and recycling system designed to process plastic waste generated during extended lunar habitation. Initial research focused on existing manufacturing and recycling technologies …

Lunar Manufacturing Systems And The Role Of Additive Recycling Technologies, Camille A. Newman

Honors Theses

Renewed international interest in sustained lunar exploration has created a growing demand for technologies to support long-duration space exploration. Part of the recent Artemis missions and the Moon to Mars initiative is to improve key mission capabilities and fill critical gaps necessary to sustain lunar habitation. Waste management, recycling systems, and manufacturing systems have been identified as critical technologies that need further development before a sustained mission is possible. This thesis explores the feasibility of an additive manufacturing and recycling system designed to process plastic waste generated during extended lunar habitation. Initial research focused on existing manufacturing and recycling technologies …

Ai-Based Porosity Detection In Babbitt Bore Turning, Kaylee Leggett, Hannah Adams Gemmell, Kaisa Shingleton

Williams Honors College, Honors Research Projects

For this project, an external company reached out to the University of Akron requesting assistance with defect detection during their vertical turning operations. As babbitt is removed in a vertical turning process, it occasionally reveals defects, mainly porosity, which can lead to costly downstream failures of the part. Current inspection techniques involve use of dye penetrant, which is time consuming, labor intensive, unergonomic, and a source of human error. The goal of the project is to create an alternative inspection method using an AI-based machine-learning model. After the turning operation, a camera is deployed to perform an in-place inspection, taking …

Optimization Of Post-Processing Methods For Additively Manufactured Metals, Julia R. Carano

Williams Honors College, Honors Research Projects

Ultrasonic Nanocrystal Surface Modification (UNSM) is a process used to change the surface hardness of flat-faced materials. It is a machining process using a high-powered laser and a blunt-tipped tool at high speeds which aims to improve the uniformity of the surface on most metals. By heating and pressing the surface of the workpiece, the grains of the material become less rounded and more cohesive on a microscopic level. This, ideally, results in a workpiece with improved material properties. The changes were previously observed through hardness testing.

From Concept To Light: Manufacturing A Dual-Purpose Bedside Lamp And Book Organizer, Nicole Goulet

Honors Theses

This report features the design, development, engineering changes, and manufacturing of the Bedside Lamp, a hand-made multi-purpose lamp, book holder, and charging hub. The investigation began with research and a market analysis on current lamp designs and a discussion about what features would set the lamp apart. This led to the design of the lamp and construction of multiple prototypes for proof of concept.

A manufacturing process was then designed to demonstrate the steps to start up an efficient and cost-effective production line. This process included obtaining raw materials, cutting them into the necessary parts, and assembling everything to create …

A Product Development Process From Concept To Production: Smartphone Projector, Ross G. Cohen, Piper G. Thomas

Honors Theses

The purpose of this thesis is to demonstrate the production and documentation of the SmartPhone Projector Capstone for the Center of Manufacturing Excellence (CME). This document follows the production development from the beginning Spring 2024 problem definition all the way to the Fall of 2024 final product. This project was completed by a team of five undergraduate students, including an accounting major, finance major, biomedical engineering major, and two mechanical engineering majors. The goal of this project was to design and build a SmartPhone projector, then carry out a full production run located on the CME shop floor. To begin …

Exploring Manufacturing Techniques For Small-Scale Metal Fabrication And How They Can Be Optimized For Efficiency, Precision, And Scalability To Produce A Fire Pit, Henry W. Potter

Honors Theses

This thesis explores manufacturing techniques for small-scale metal fabrication, using a fire pit production as a case study to optimize efficiency, precision, and scalability. The study examines the challenges of small-scale manufacturing and analyzes alternative manufacturing techniques for cutting, joining, and surface finishing. Data was gathered through a case study involving the design and production of a fire pit. The manufacturing process included cutting, rolling, joining, and surface finishing. Alternative techniques, such as laser cutting and a paint sprayer, were compared to the methods used in the project. It was concluded that alternate methods offered improvements in efficiency, precision, and …

Thermal Characterization Of 3d Printing Materials For Increasing Insulation Potential And Practicality, Jackson H. Minnick

Mechanical Engineering Undergraduate Honors Theses

This study served as an exploration into the possible existence of a correlation between the infill lattice structure of a 3D printed wall section and the thermal performance of that sample as characterized by thermal conductivity measured in units of Watts per meter Kelvin. With the continual increase in the practicality, fidelity, and applicable fields of additive manufacturing, namely FDM 3D printing, research on specific print characteristics and their effects on the material and thermal characteristics of the part in question is steadily becoming more commonplace. Although the thermal conductivity of 3D printed wall sections as a function of infill …

Carbon Fiber Cv Tripod Axle Design: Husker Motorsports Formula Sae, Taylor D. Boudreaux

Honors Program: Senior Projects (Public)

The 2024–2025 HMS Formula SAE senior design team successfully reduced axle system weight, cost, and improved manufacturability using a bonded tripod joint and ±45° intermediate modulus carbon fiber tube. The final design was validated on HMS 25, with no failures under rigorous testing.

Budget:
/="/"> Total project cost was $1,165.64, exceeding the initial $1,000 target due to unanticipated test rig expenses. However, per-axle production cost was reduced from $525.31 to $383.37 through in-house manufacturing, use of on-hand epoxy (DP460), and switching to cost-effective 7068 aluminum. The axle-specific cost was $766.74.

Timeline:
/="/"> Despite early delays from building a torsional testing …

Development Of Planetary Drive System For Formula Sae Electric Race Car, Brian Wong, Bradley Maruoka, Joshua Charles Fine, Madison Kai

Mechanical Engineering

Hub motors are compact electric motors mounted directly on each outboard wheel hub. Utilized in Formula SAE and Formula Student vehicles, this configuration offers several advantages over traditional drivetrains, including packaging optimization within the chassis, vehicle traction, and improved efficiency. Although hub motors are not yet common in 4WD vehicles, they are being explored for use in EVs and may become more common in the future. Every year, Cal Poly Racing FSAE designs and builds a formula-style race car. To improve drivetrain performance, the team is investigating the achievability of a hub motor 4WD drivetrain, requiring extensive research, development, and …

Transient Thermal Finite Element Simulation For Process Modeling In Wire Arc Additive Manufacturing, Satya Sai Kumar Pilli

Dissertations, Master's Theses and Master's Reports

This thesis presents the development of a transient thermal framework for Wire Arc Additive Manufacturing (WAAM) created using ANSYS Workbench. This study aims to understand the inherent properties and thermal behavior of WAAM by using the Finite Element (FE) simulation technique to reduce the need for experiments. Specifically, the transient thermal WAAM simulation framework uses the heat source Goldak model to understand the thermal behavior for a given voltage, initial temperature, and travel speed during the process to predict process temperature. The outcomes of this thesis aim to significantly decrease material waste and repetitive experiments and accelerate production process design …

High Voltage Junction Box For Demonstrator Vehicle, Benjamin Lubowicki, Ryan Dorste

Williams Honors College, Honors Research Projects

Schaeffler, our industry sponsor for this project, is designing a battery pack for a demonstration vehicle that requires a high voltage junction box to route power to the vehicle. The project type is a unique design of a mechanical component, mechanism, and process. Our objective for this project is to assemble provided electro-mechanical components into an enclosure following a provided electrical diagram. The expected deliverables are the following: 3D CAD assembly of final product, FEA analysis of designed components, 2D print of final product, fabrication and assembly of designed parts, technical report documenting design process and installation. The skills required …

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 …

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 …

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 …

Development, 3d Printing, And Sintering Of Aluminum-Magnesium Alloy Pastes For In-Space Manufacturing Applications, Fatou Ndiaye

Electronic Theses and Dissertations

This study explores the additive manufacturing process of paste printing, sintering, and de-binding for fabricating aluminum-magnesium alloy components. The paste formulation involved combining aluminum powder with varying magnesium concentrations, utilizing acrylic polyol, solvent, and plasticizer to create a homogeneous mixture. Printing parameters were optimized to ensure continuous pressure for improved extrusion. Sintering conditions involved incremental temperature increases with nitrogen flow to remove solvents. Density measurements, tensile tests, and shrinkage calculations were conducted to assess part quality post-sintering. The study revealed significant improvements in part quality with 5 wt.% magnesium incorporation within aluminum, although density and tensile strength fell short of …

Liquid Nitrogen Shrink-Fitting Process, Natalie Harvey

The Journal of Purdue Undergraduate Research

No abstract provided.

Navigating The Complexities Of Engineering Management: Insights Into Metrics, Measurements, And Pitfalls, Charles Daniels

Engineering Management & Systems Engineering Faculty Publications

In the realm of Engineering Management, the reliance on metrics and measurements stands as a cornerstone for effective decision-making processes. These quantitative tools offer insights into performance dynamics and facilitate informed strategic choices. However, the uncritical application of metrics devoid of profound domain expertise presents significant challenges. This abstract explores the pitfalls inherent in utilizing metrics and measurements within Engineering Management without comprehensive understanding, emphasizing the potential consequences and proposing strategies for navigating this complex terrain.

Energy Efficiency In Additive Manufacturing: Condensed Review, Ismail Fidan, Vivekanand Naikwadi, Suhas Alkunte, Roshan Mishra, Khalid Tantawi

Engineering Technology Faculty Publications

Today, it is significant that the use of additive manufacturing (AM) has growing in almost every aspect of the daily life. A high number of sectors are adapting and implementing this revolutionary production technology in their domain to increase production volumes, reduce the cost of production, fabricate light weight and complex parts in a short period of time, and respond to the manufacturing needs of customers. It is clear that the AM technologies consume energy to complete the production tasks of each part. Therefore, it is imperative to know the impact of energy efficiency in order to economically and properly …