Manufacturing Commons^™

Fabrication And Characterization Of Cast Copper Heatsinks For Computer Chip Cooling, John James Recktenwald

Graduate Theses, Dissertations, and Problem Reports (ETD)

Humanity has worked copper for millennia, from primitive tools in prehistory to the wires and cooling solutions facilitating the modern digital age. While high performance fin style heatsinks are commonplace, more complex heatsink geometries in high performance applications are rare due to manufacturing challenges. In this study a casting process was developed to fabricate copper pin fin heatsinks. To assess the performance of heatsinks fabricated using the process three pin fin heatsinks were fabricated, one machined from a commercially manufactured billet, one machined from a cast block, and one cast directly to final shape. Each of the three heatsinks were …

Comparison Of Cnn And Lstm Networks On Human Intention Prediction In Physical Human-Robot Interactions, Khosro Ghorbani Zadeh, Niloofar Zendehdel, George L. Holmes, Keyri Moreno Bonnett, Amy Costa, Devin Michael Burns, Ming-Chuan Leu, Yun Seong Song

Psychological Science Faculty Research & Creative Works

Advancements in robotics and AI have increased the demand for interactive robots in healthcare and assistive applications. However, ensuring safe and effective physical human-robot interactions (pHRIs) remains challenging due to the sophistication of human motor communication and intent recognition. Traditional physics-based models struggle to capture the dynamic nature of human force interactions, limiting robot adaptability. To address these limitations, neural networks (NNs) have been explored for force-movement intention prediction. While multi-layer perceptron (MLP) networks show potential, they struggle with temporal dependencies and generalization. Long Short-Term Memory (LSTM) networks effectively model sequential dependencies, while Convolutional Neural Networks (CNNs) enhance spatial feature …

Molecular Dynamics-Based Two-Dimensional Simulation Of Powder Bed Additive Manufacturing Process For Unimodal And Bimodal Systems, Yeasir Mohammad Akib, Ehsan Marzbanrad, Farid Ahmed

Manufacturing & Industrial Engineering Faculty Publications

The trend of adapting powder bed fusion (PBF) for product manufacturing continues to grow as this process is highly capable of producing functional 3D components with micro-scale precision. The powder bed’s properties (e.g., powder packing, material properties, flowability, etc.) and thermal energy deposition heavily influence the build quality in the PBF process. The packing density in the powder bed dictates the bulk powder behavior and in-process performance and, therefore, significantly impacts the mechanical and physical properties of the printed components. Numerical modeling of the powder bed process helps to understand the powder spreading process and predict experimental outcomes. A two-dimensional …

Exploration Of The Iterative Design Process: Integrating A Requirements Matrix And Hazard Analysis Toolsexploration Of The Iterative Design Process: Integrating A Requirements Matrix And Hazard Analysis Tools, Blaine Edlefsen

Theses

The iterative design process is applied to multiple industry sectors from software development to product manufacturing. The cyclical approach integrates the steps of design, prototyping, and testing toward the realization of a user's specified needs. The use of a requirements traceability matrix and hazard analysis documentation that supports the definition of the iterative design process is explored. These design project management tools are applied to a case study involving workholding design for a Wire Electrical Discharge Machining (Wire-EDM) manufacturing process. This industry-relevant case study is conducted in collaboration with New Jersey Precision Technologies, Incorporated (NJPT). The design requirements involve both …

Nano-Second Pulsed Laser Ablation Of Inconel 718 And Mmpcd For Simultaneous Optimal Ablation Rate And Surface Quality, Ahmed Elkaseer, Islam Abdelgaliel, Jon Lambarri, Iban Quintana, Steffen Scholz, Mohamed Aly

Mechanical Engineering

This study investigates the ablation performance of Inconel 718, a nickel-based superalloy, and metalmatrix polycrystalline diamond (MMPCD), a super composite, using a nano-second (ns) pulsed laseracross a range of ablation conditions. Single trenches varying in energy fluence and scanning speedswere created, analyzing the experimental responses in terms of ablation rate and surface roughness.Using regression techniques, models were developed to understand these relationships. Four multi-objective optimization algorithms, weighted value grey wolf optimizer (WVGWO), multi-objectivePareto search (MOPS), multi-objective genetic algorithm (MOGA), and multi-objective sunfloweroptimization (MOSFO), were employed to optimize these models. Key findings include MMPCDachieving the highest ablation rates at maximum fluence …

Using Additive Manufacturing To Characterize Effects Of Sparse Infill Density And Sparse Infill Pattern On The Compressive Properties Of Short Strand Carbon Fiber Infused Petg, Luke C. Salisbury

Honors Theses

The advent of additive manufacturing has revolutionized the prototyping, design, and manufacturing of new and innovative products. Through the use of Fused Deposition Modeling (FDM), parts can be manufactured using different sparse infill percentages (the percentage of void space within a printed object) and sparse infill patterns (the lattice structure of material within the object). Through the manipulation of these variables, the same material and part can have different compressive and flexural properties. In addition to sparse infill, the thermoplastics used in fused deposition modeling can be reinforced with carbon fiber strands to create a printable composite material capable of …

Greek Key-Inspired Fractal Metamaterials With Enhanced Flexibility And Energy Absorption., Zhennan Zhang

Electronic Theses and Dissertations

Architected materials with intricate three-dimensional (3D) geometries offer unique properties and functionalities but face challenges in manufacturing costs and complexity. This research explores the integration of simple 2D Greek Key-inspired lattices into fractal designs to achieve exceptional mechanical performance. Using 3D printing and kerfing, these fractal structures demonstrate enhanced flexibility and energy absorption capabilities. Through three-point bending and in-plane tensile tests, the 2D fractal lattices exhibited a 600-fold reduction in bending force and a tensile stretch capacity of up to 520%, significantly outperforming brittle parent materials. Out-of-plane compression tests revealed a five-fold increase in energy absorption compared to honeycomb structures, …

Modeling And Understanding Of Additive Manufacturing Periodic Cellular Structures With Heterogeneity: Property, Quality And Design Strategy., Naresh Koju

Electronic Theses and Dissertations

Lightweight cellular structures with their higher per mass performance capability, multifunctional designability and property tolerability are gaining much wider adaptation in many engineering applications ranging from aerospace, defense, biomedical, automotive to sports. However, to achieve the desired performance levels careful design must be carried out. The experimental-based empirical design often involves high manufacturing cost, and there are also certain information/knowledges about the cellular deigns that could not be easily obtained experimentally, such as the deformation local fracture initiation. Similarly, numerical modeling-based design approach commonly suffers from high computation cost and the lack of inverse designability. In addition, numerical models often …

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, …

Hitch Cart “Landing Gear”, Rebekah White, Jose Raygoza, Randy Hernandez, Brandon Leon

Mechanical Engineering

This report aims to allow our sponsor, to review our design process of the Hitch Cart Landing Gear Prototype. In the design overview section of this report, we discuss the primary design modifications we made to the wheel mechanism of the existing hitch cart prototype, including the addition of the ACME screws and the folding brackets. This allows our sponsor to see the intended improvements made to the past prototype and understand the primary goal of our project. Then, in the implementation section, we cover the entire manufacturing process to allow our sponsor to understand what manufacturing steps must be …

Expandable And Retractable Wheel Design, Ethan Fortenberry, Emily Cottrell, Keegan Martin, Benjamin Mcconnell

Mechanical Engineering

Our sponsor, Jeremy Goren, wants to see his patented expandable wheel design come to life. He requires a functional final product actuated by linear actuators and with a continuous, circular outer shell. The overall design can be broken up into 2 parts: the inner hub and outer shell. The wheel's shell will consist of a 12-piece outer shell that guides the 6 inner shell pieces. The outer shell pieces will be connected via a UBracket. The hub will consist of 3 identical parts that will hold 2 linear actuators each. The pieces will be bolted together to create 1 singular …

The Waterbug: Adaptive Paddle Board Frame, Remy James Elio Lacchia, Katie Kellum, Madeline Evenson, Shelbi Sullaway

Mechanical Engineering

People with disabilities, particularly wheelchair users, face limitations in participating in outdoor activities like paddleboarding. Central Cal Adaptive, a nonprofit organization, aims to bridge this gap by offering adapted paddleboarding experiences. However, their current paddleboard presents challenges such as portability, range of motion, stability, and safety. Our team, comprising Madeline Evenson, Remy Lacchia, Katie Kellum, and Shelbi Sullaway, has collaborated with Central Cal Adaptive to refine the existing paddleboard design. The team’s goal is to enhance the paddleboard's functionality to better cater to wheelchair users' needs, ensuring lightweight, portable, and safe features for an improved outdoor experience.

Our paddleboard concept …

Development Of A Manifold Microchannel Heat Sink For The Electrification Of Aircraft, Joshua Mora Sanchez

Mechanical Engineering Undergraduate Honors Theses

The miniaturization of microprocessors and power electronics is leading to critical thermal management challenges. For instance, the heat flux generated in modern computer chips is at the order of 100W/cm², which is well beyond the limit of air cooling. This high heat generation can cause a variety of thermal or mechanical failures in electronic devices. As such, there is a pressing need to devise effective cooling strategies for these microelectronic devices. Liquid cooling with microchannel heat sinks is a promising technology for high power loads. Nevertheless, traditional heat sinks with straight microchannels suffer from two critical challenges: high pressure drop …

Sensitive Grip Mounting Surfaces For Physical Human-Robot Interaction., Branden Shay

Electronic Theses and Dissertations

As the development of robotics becomes ever increasingly present in our society, the need for studying how humans and robots interact with each other becomes more of a necessity to be properly integrated in the changing world around us. In this thesis, we undertake the study and development of how to create a tactile human-robot operator interface to guide a robot perform a physical task. The implementation of tactile interfaces such as SkinCell sensor arrays emulating skin, and of a robotic handlebar fitted with tactile sensors are critical examples of the challenges that come with mounting and packaging such sensors …

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 …

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 …

Fabrication And Performance Of Scalable Bio-Engineered Porous Layers For Efficient Co2 Capture, Mary Sharon Rose Bondugula

Theses and Dissertations

This dissertation addresses the critical challenge of mitigating climate change by advancing CO2 capture technologies. As global CO2 emissions continue to rise, effective methods for capturing and separating CO2 from industrial processes are essential to combat climate change. Existing CO2 capture systems, such as Pressure Swing Adsorption (PSA) and Temperature Swing Adsorption (TSA), often rely on packed bed designs that face limitations, including poor heat and mass transfer, slow gas diffusion, and low thermal conductivity, reducing their efficiency. To overcome these challenges, this dissertation explores innovative solutions by developing advanced adsorbent coatings and scalable bed configurations.

This research begins by …

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 …

A Study Of Fit And Friction Force As A Function Of The Printing Process For Fff 3d-Printed Piston–Cylinder Assembly, Philippe A. Passeraub, Quentin Allen, Elizabeth Clark, Michael Miles, Siddartha Berns, Maija Pearson, Sterling Allred, Jonah Brooks, Sylvain Hugon

ScholarsArchive Data

Dataset DOI: https://doi.org/10.26067/hjm6-3d45

The shared data comprises the experimental measurements performed presented in the figures 5, 6, 7, 9, 10, 11, 12, and in the tables for the following article:

Passeraub, P.A.; Allen, Q.; Clark, E.; Miles, M.; Berns, S.; Pearson, M.; Allred, S.; Brooks, J.; Hugon, S. A Study of Fit and Friction Force as a Function of the Printing Process for FFF 3D-Printed Piston–Cylinder Assembly. J. Manuf. Mater. Process. 2024, 8, 249. https://doi.org/10.3390/jmmp8060249

Development Of Multifunctional Wood Composites With Integrated Phase Change Materials For Enhanced Thermal Management, Self-Healing, And Sustainability., Emmanuel Igbokwe

LSU Master's Theses

Abstract

This study focused on incorporating self-healing, flame retardancy, and energy harvesting capabilities into the wood composite to contribute to more sustainable and energy-efficient building practices. Oriented strand board has been widely used as sheath for roofing or dry walls in residential buildings. Residential buildings account for a large portion of energy consumption. Therefore, an oriented strand board with energy harvesting capability is highly desired. Additionally, flame retardancy and damage self-healing and end-of-life recycling are also critical features for buildings.

In this study, we prepared a novel oriented strand board by constructing sandwich structures. The face sheets of the sandwich …

Development Of Robust Steel Alloys For Laser-Directed Energy Deposition Via Analysis Of Mechanical Property Sensitivities †, Jonathan Kelley, Joseph W. Newkirk, Laura N. Bartlett, Sriram Praneeth Isanaka, Todd Sparks, Saeid Alipour, Frank Liou

Materials Science and Engineering Faculty Research & Creative Works

To ensure consistent performance of additively manufactured metal parts, it is advantageous to identify alloys that are robust to process variations. This paper investigates the effect of steel alloy composition on mechanical property robustness in laser-directed energy deposition (L-DED). In situ blending of ultra-high-strength low-alloy steel (UHSLA) and pure iron powders produced 10 compositions containing 10–100 wt.% UHSLA. Samples were deposited using a novel configuration that enabled rapid collection of hardness data. The Vickers hardness sensitivity of each alloy was evaluated with respect to laser power and interlayer delay time. Yield strength (YS) and ultimate tensile strength (UTS) sensitivities of …

Mechanical Properties Of Polymer Matrix Nanocomposites Reinforced With Varying Carbon Nanotube Geometries, Ethan Gaigalas, Zoe Kelemen

College of Engineering Summer Undergraduate Research Program

This study serves as part of an introduction to nanocomposite research at California Polytechnic State University, San Luis Obispo, and attempts to form an observational comparison between the performance of various CNT-Epoxy nanocomposites under drop weight testing. As a continuation of research on CNT-Epoxy nanocomposites, this study specifies three geometries of Multi-walled carbon nanotubes: straight (MWSCNTs), helical (MWHCNTs), and OH-functionalized straight (FMWSCNTs); and it compares their impact resistances to neat epoxy samples. Based on the total number of failed samples under a normalized impact energy of 0.335J/mm, it is observed that FMWSCNTs increase the impact resistance of Epoxy panels at …

Design Of Ballistics Armor Using Additive Manufacturing Of Kevlar Composites, Jedidiah D. Jimenez, Roha Y. Ali, Jack C. Bride

College of Engineering Summer Undergraduate Research Program

This project evaluates the effectiveness of various geometries created using advanced additive manufacturing (AM) of Kevlar fiber, chopped carbon fiber-reinforced filament for ballistic protection applications. This study expands on sandwich panel designs with woven Kevlar face sheets and investigates an optimal fiber reinforced filament core structure design. A unit cell workflow was developed in nTop to take advantage of its custom cell modeling and FEA capabilities. Unit cell types were simulated and tested from the hexagonal honeycomb, gyroid TPMS, and re-entrant auxetic cell families. Core structure thickness and cell size were additive manufacturing parameters that were varied to assess the …

Gaze Tracking Embedded Collaborative Robots For Automated Metrology And Reverse Engineering, Sachithra H. Karunathilake, Md Shahriar Forhad, Zhaohui Geng

Manufacturing & Industrial Engineering Faculty Publications

Conventional geometric metrology, or three-dimensional (3D) scanning, and reverse engineering heavily rely on the experience of the operators. With an increasing need for automation, robot arms have been adopted for this task. However, due to the large variety of parts and designs, automated path planning could provide a scanning solution that may overlook the critical area, which could potentially deteriorate the scan results. This article explores the integration of collaborative robotics (cobots) with eye-tracking technology to improve the autonomous 3D scanning process. The primary objective of this study is to enhance the accuracy and efficiency of cobots in 3D scanning, …

Prediction Of Tool Wear And Surface Finish Using Anfis Modelling During Turning Of Carbon Fiber Reinforced Plastic (Cfrp) Composites, Anil K. Srivastava, Md. Mofakkirul Islam

Manufacturing & Industrial Engineering Faculty Publications

Carbon fiber-reinforced plastics (CFRP) are widely used in various industries due to their high strength to weight ratio, corrosion resistance, durability, and excellent thermo-mechanical properties. The machining of CFRP composites has always been a challenge for the manufacturers. In this study, CNC turning operation with coated carbide tool is used to machine a specific CFRP and the relationship between the cutting parameters (Speed, Feed, Depth of Cut) and response parameters (Vibration, Surface Finish, Cutting Force and Tool Wear) are investigated. An adaptive-network-based fuzzy inference system (ANFIS) model with two multi-input–single-output (MISO) system has been developed to predict the tool wear …

Data-Driven Roughness Estimation Of Additively Manufactured Samples Using Build Angles, Jose Galarza, Jose Barron Jr., Farid Ahmed, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications

Achieving control of Laser Powder Bed Fusion (L-PBF) over the quality of the print is the main motivation for finding an optimum set of parameters in the process. Surface roughness is one of the characteristics of the print that impacts the performance of the desired functionality. This research focus is to relate the build angle with the surface roughness on the L-PBF printed specimens and utilize machine learning methods for roughness estimation of geometric features with varying build angles. The EOS M290 L-PBF printer was used to print Inconel-718 coupons using standard process parameters while varying build angles from 20 …

Enhancing Resilience In Complex Energy Systems Through Real-Time Anomaly Detection: A Systematic Literature Review, Ali Aghazadeh Ardebili, Oussama Hasidi, Ahmed Bendaouia, Adem Khalil, Sabri Khalil, Dalila Luceri, El Hassan Abdelwahed, Sara Qassimi, Antonio Ficarella

Manufacturing & Industrial Engineering Faculty Publications

As real-time data sources expand, the need for detecting anomalies in streaming data becomes increasingly critical for cutting edge data-driven applications. Real-time anomaly detection faces various challenges, requiring automated systems that adapt continuously to evolving data patterns due to the impracticality of human intervention. This study focuses on energy systems (ES), critical infrastructures vulnerable to disruptions from natural disasters, cyber attacks, equipment failures, or human errors, leading to power outages, financial losses, and risks to other sectors. Early anomaly detection ensures energy supply continuity, minimizing disruption impacts, an enhancing system resilience against cyber threats. A systematic literature review (SLR) is …

Emerging Productivity And Advanced Equipment Manufacturing: Issues, Reflections, And Practices, Jianlin Cao

Bulletin of Chinese Academy of Sciences (Chinese Version)

An important aspect of developing new quality productivity is utilizing the latest scientific and technological advancements for industrial upgrading, which includes developing emerging industries (high-tech industries) and transforming traditional industries. The weakness in advanced equipment manufacturing is a key challenge in China’s current industrial upgrading. This study, based on the global distribution of manufacturing enterprises, proposes a classification of four types of enterprises. It explains the reasons behind China’s lack of the fourth type of enterprise (those capable of integrating the latest technological achievements into their produced equipment) and the difficulties in cultivating and developing such enterprises. The study also …

Research On Development Status And Strategy Of Advanced Materials In Guangdong-Hong Kong-Macao Greater Bay Area, Ziwei Zhao, Can Wang, Weihua Wang, Qingli Huang

Bulletin of Chinese Academy of Sciences (Chinese Version)

Advanced materials are an important source of new quality productivity. Guangdong-Hong Kong-Macao Greater Bay Area is now facing the internal and external pressure of manufacturing upgrading, and there is an urgent need to play the leading and supporting role of advanced materials in the construction of modernized industrial system. This study combs through the basic situation of the development of materials science and industry in Guangdong-Hong Kong-Macao Greater Bay Area, analyzes its advantages, characteristics and problems in depth, and puts forward a number of suggestions around how to develop materials science, technology, and industry in the Greater Bay Area.

Investigation Of Distributed Additive Manufacturing For 3d Printed Headband Component During Global Supply Chain Disruptions, Elizabeth M. Mamros, Saketh Kantipudi, Matthew C. Eaton, Jinjin Ha, Brad L. Kinsey

Faculty Conference Papers and Presentations

During the COVID-19 global pandemic, a shortage of personal protective equipment (PPE) occurred. Manufacturers of these critical products were unable to keep up with the growing demands as the situation evolved. Most face shields, a common type of PPE, include a headband component to provide the appropriate fit for the user and curvature for the clear face shield attachment. To mitigate this shortage in the local region, the Portsmouth Naval Shipyard (PNSY) generated a computeraided design (CAD) file for the headband component and asked the University of New Hampshire (UNH) to manufacture it with all available 3D printers, including printers …