Manufacturing Commons^™

Stakblocks, Micah Satoshi Inoshita, Ava Rose Doerschlag, Cody J. Ellis, Zach M. Lawton, Fernando M. Nalin, Nicholas Humphrey, Aiden Reed Anderson, Sara Maya Suratkal

Mechanical Engineering

Researchers developing sustainable building materials from agricultural waste need a faster way to prototype and evaluate small-scale samples under controlled temperature and pressure before scaling to production. Sponsored by Professor Pete Schwartz of Cal Poly San Luis Obispo, whose work focuses on sustainable technology for developing communities, this project aims to create a prototype testing device for researchers studying agricultural-waste bricks, with the University of Malawi as a potential future testing partner. The final product is intended to inform improved future designs rather than serve as a production-ready device, ultimately supporting the development of affordable, sustainable building materials for communities …

Fpga-Based Sensors For Distributed Digital Manufacturing Systems: A State-Of-The-Art Review, Laraib Khan, Sriram Praneeth Isanaka, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The combination of distributed digital factories (D2Fs) with sustainable practices has been proposed as a revolutionary technique in modern manufacturing. This review paper explores the convergence of D2F with innovative sensor technology, concentrating on the role of Field Programmable Gate Arrays (FPGAs) in promoting this paradigm. A D2F is defined as an integrated framework where digital twins (DTs), sensors, laser additive manufacturing (laser-AM), and subtractive manufacturing (SM) work in synchronization. Here, DTs serve as a virtual replica of physical machines, allowing accurate monitoring and control of a given manufacturing process. These DTs are supplemented by sensors, providing near-real-time data to …

Natural Fiber Reinforced Composites For Sustainable Additive Manufacturing., Athira Nair Surendran

Electronic Theses and Dissertations

Carbon fiber is widely known for its exceptional strength, making it a sought-after material in composite manufacturing, especially with thermosets and thermoplastics. Its major applications span aerospace, wind turbines, sports equipment, automotive interior and exterior parts, robotics and medical equipment. Recently, carbon fiber filament manufacturing has gained attention due to the availability of desktop 3D printers and the versatility and customizability that comes with the realm of 3D printing. Commercial carbon fiber production, primarily from polyacrylonitrile (PAN), is energy-intensive and derived from crude oil, contributing to significant environmental impacts and poor recyclability. Alternatively, lignocellulosic natural fibers present a possible sustainable …

Sustainable Phone Housing, Jonah Milnor

All Undergraduate Projects

Most commercially available smartphones posed a challenge to consumers due to the use of adhesives, which not only served to seal out dust and water but also hindered repairability and hardware replacement. Drawing inspiration from successful smartwatch designs employing gaskets for water resistance, this project aimed to adapt such design principles to the smartphone form factor.

Utilizing SolidWorks for design and subsequent 3D printing and CNC machining for prototyping, 3D models of a smartphone housing were crafted. The objective was to attain a level of water and dust resistance equivalent to that of model smartphones, utilizing sealing methods equivalent to …

Urban Farming: Empowerment To Increase Economic, Education, And Nutritional Benefit For The Sub-Urban Community, Nasruddin Nasruddin, Yusuf Donner Dwiyantama, Banu Muhammad, Anom Bowalaksono, Dian Ayubi, Sarah Islamiati Pertiwi

ASEAN Journal of Community Engagement

This article discusses the urban farming program at Sekolah Master in Beji, Depok, Indonesia, which aims to provide the community with broader benefits, such as economy, education, and increased nutritional value. The project involves planting method that was introduced to this school community. The program itself consists of several stages, starting from the preparation—dissemination of the program and designing a plan for the greenhouse, the implementation—constructing the greenhouse and installing the automatic water system, planting the vegetation, and monitoring and evaluation of the program. Eventually, an evaluation of the successful program is required to determine whether the program can be …

Trade-Off Characterization Between Social And Environmental Impacts Using Agent-Based Models And Life-Cycle Assessment, Joseph C. Leichty, Christopher S. Mabey, Christopher A. Mattson, John L. Salmon, Jason Weaver

Faculty Publications

Meeting the UN’s sustainable development goals requires designers and engineers to solve multi-objective optimization problems involving trade-offs between social, environmental, and economic impacts. This paper presents an approach for designers and engineers to quantify the social and environmental impacts of a product at a population-level and then perform a trade-off analysis between those impacts. In the approach, designers and engineers define the attributes of the product as well as the materials and processes used in the product’s life cycle. Agent-Based Modeling (ABM) tools that have been developed to model the social impacts of products are combined with Life- Cycle Assessment …

Laptop Recycling Case Study: Estimating The Contained Value And Value Recovery Process Feasibility Of End-Of-Life Consumer Electronics, Zebulon Hart

Theses and Dissertations--Mining Engineering

Work has been done to establish, through the development and use of novel assay techniques and analysis metrics, the contained value of a sampling of laptop computers (as an analog for myriad e-waste sources). This work has conceptualized e-waste as an alternative to geologic-origin complex metallic ores and has likewise evaluated the feasibility of value recovery from e-waste sources in a similar manner to an ore. The application of conventional and novel mineral separation techniques to e-waste recycling processes has been evaluated and positive results are demonstrated. Further, this work has demonstrated the ability to identify the presence of base …

Sustainability Assessment Of Direct Energy Deposition (Ded) Based Hybrid Manufacturing Using Life Cycle Assessment (Lca) Method, Faujia Islam

Graduate Theses, Dissertations, and Problem Reports (ETD)

As sustainability has emerged as a highlight for almost every field over the last few decades, the manufacturing field is no exception. Generally, additive manufacturing performs better than traditional manufacturing in terms of sustainability because of its lean energy- and material usage. Previous studies have compared the sustainability performance between traditional and additive manufacturing, but hybrid manufacturing was not focused upon much. In this paper, the life cycle assessment method is used to analyze and compare the energy consumption and environmental impact of direct energy deposition (DED) based hybrid manufacturing and traditional manufacturing “CNC milling” process for a turbine blade. …

Utilization Of Recycled Filament For 3d Printing For Consumer Goods, Alexa Peterson

Apparel Merchandising and Product Development Undergraduate Honors Theses

The 3D printing market has been used in a wide variety of manufacturing industries including textile and apparel. Many consumers can now own a personal 3D printer at home for recreational printing. There are even websites dedicated to 3D printing patterns made by consumers. However, the materials used in the 3D printing process pose a problem for the environment due to their plastic-based nature. 3D printing is a layered process with each layer being printed depending on the layer below it for strength and stability. During the 3D printing process, great amounts of waste are produced as a result of …

Novel Methods For Composites Recycling Via Pyrolysis, Matt Jacobs

Undergraduate Honors Theses

Composites are unique materials in many respects. When fabric woven from carbon fibers is joined with a thermoset resin in a controlled environment, it results in a very strong material, especially evaluated on a pound-for-pound basis against metals and ceramics. One aspect of this construction that provides great strength lies in the fiber-matrix adhesion which facilitates load transfer to the reinforcement of the composite. This fiber-matrix adhesion is promoted by the polarity of the usual thermoset matrices, and properly designed sizing materials coating the fibers. It’s a two-edged sword, though. Although the resin and the fibers are quite strong together, …

Process Sustainability Evaluation For Manufacturing Of A Component With The 6r Application, Ana E. Bonilla Hernández, Tao Lu, Tomas Beno, Claes Fredriksson, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

Sustainability in manufacturing can be evaluated at product, process and system levels. The 6R methodology for sustainability enhancement in manufacturing processes includes: reduced use of materials, energy, water and other resources; reusing of products/components; recovery and recycling of materials/components; remanufacturing of products; and redesigning of products to utilize recovered materials/resources. Although manufacturing processes can be evaluated by their productivity, quality and cost, process sustainability assessment makes it a complete evaluation. This paper presents a 6R-based evaluation method for sustainable manufacturing in terms of specific metrics within six major metrics clusters: environmental impact, energy consumption, waste management, cost, resource utilization and …

Designing And Redesigning Products, Processes, And Systems For A Helical Economy, Ryan Bradley, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

The Circular Economy (CE) concept has promised to unlock trillions of dollars in business value while driving a significant reduction in the world’s resource consumption and anthropogenic emissions. However, CE mainly lives in ambiguity in the manufacturing domain because CE does not address the changes needed across all of the fundamental elements of manufacturing: products, processes, and systems. Conceptually, CE is grounded in the concept of closed-loop material flows that fit within ecological limits. This grounding translates into a steady state economy, a result that is not an option for the significant portion of the world living in poverty. Therefore, …

Database Design For The Collection And Visualization Of Sustainabilty Data, Henry A. Kozlowski, Nikhila Perugupalli

Industrial and Manufacturing Engineering

The goal of the project was to create a database that would be a repository for the high volume of sustainability data Illumina would like to collect. To couple with the database the project team’s goal was to design a system for visualizing the data graphically. Illumina required a database system that would be user-friendly, easy to add, delete, and edit data inputs, as well as a program that would allow the user to easily sort and graph data. The intent of the graphical representation of the data is to publish the graphs in a monthly report that would be …

A Framework For Sustainable Material Selection For Multi-Generational Components, Ryan T. Bradley

Theses and Dissertations--Mechanical and Aerospace Engineering

The early stages of a product’s design are a critical time for decisions that impact the entire life-cycle cost. Product designers have mastered the first generation; however, they currently do not have the ability to know the impact of their decisions on the multi-generational view. This thesis aims at closing the gap between total life-cycle information and the traditional design process in order to harbor sustainable value creation among all stakeholders involved. A framework is presented that uses a combination of a life-cycle costing methodology and an evolutionary algorithm in order to achieve a sustainability assessment for a true multi-generational …

The Sustainability Of Lean Manufacturing As A Competitive Advantage, Louis G. Jones

Theses and Dissertations

Since the early 1990s lean manufacturing has been employed by companies looking to reduce costs, increase efficiencies and improve quality. Academic studies of the financial benefits of lean manufacturing are mixed in their results, where some show benefit and others do not. The objective of the current work was to confirm a financial benefit of lean manufacturing, while also establishing whether such a financial advantage was sustainable. Financial data was collected for a large number of companies in the manufacturing sector, over the period from 1990 to 2010. The data were used to show correlation between inventory turns and return …

Supplier Sustainability Evaluation Utilizing Multi Attribute Utility Modeling, Scott E. Ladd

Theses and Dissertations--Manufacturing Systems Engineering

Conventionally, the focus during supplier evaluation has been to assess cost, quality and delivery effectiveness due to their impact on profitability. In recent years, there has been increased emphasis on promoting more sustainable business practices that focus on reducing environmental impact and improve societal well-being, in addition to economic benefits. However, most of the existing supplier evaluation methods in literature as well as those used by leading companies fall short of comprehensively assessing suppliers from a Triple Bottom Line (TBL) perspective. TBL defined as holistically looking at the economic, environmental, and societal aspects of an entity. This paper presents a …

Sustainability For Die Manufacturing: Comparative Study Of Wedm And Milling, Matthew S. Kalus

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Sustainability is more important in today's culture due to the increasing demand for a more eco-friendly society. Concentrations in minimizing and reducing environmental impacts, energy and natural resources have been forthcoming in industry. The tool, mold and die industries are the most well known industries that machine harder materials using mills and WEDM. The objective of this thesis was to compare the sustainability differences in both of these machines utilizing the accepted standards for evaluating the manufacturing process performance for sustainability. These standards include the evaluation of the process parameters, raw materials, power, tools and fluids which all contribute to …

Modeling And Optimization To Evaluate Sustainability Performance Of Customizable Product Service Systems, Ken Harsha Tilakaratne Wijekoon

University of Kentucky Master's Theses

The aim of this thesis is to present a new methodology to evaluate and optimize sustainability of customizable product-service systems while ensuring economic, environmental and societal constraints are also satisfied. Activities across the total product lifecycle are considered to develop a model that evaluates closed-loop flow, while being monitored through the growth, maturity and decline stages of the product to provide a comprehensive analysis. A novel method to evaluate the customer satisfaction is also presented. The research considers a modular product where customization can be achieved by selecting from alternatives while ensuring the compatibility between these alternatives. A manufacturer will …