Engineering Design, Manufacturing and Management Systems Senior Design Presentations
INTEGRATED AUTOMOTIVE PHONE HOLDER
by: Grace Hansen, Jeffrey Oard, Luis Ruiz, and Jackson Sage
Sponsor: None
Faculty Advisor: David Middleton, IDSA
8:00 a.m. to 8:25 a.m.
The integration of smartphones in automobiles poses a gray area in prevention of smartphone use while driving. Following concept sketches, phone holder prototypes were created using CAD software and 3D printing. The proposed integration can safely merge smartphones with vehicles, providing an important feature in the automobile industry's goal of reducing accidents caused by texting while driving.
DESIGN OF EXTERIOR RESIDENTIAL LIGHTING FIXTURE
by: Nicholas Corey, Christopher English, Jordan Lentz, and Joseph Sulpizio
Sponsor: Cedaridge Condominium Association
Faculty Advisor: David Middleton, IDSA
8:30 a.m. to 8:55 a.m.
There’s a need to replace outdated wall-mounted lighting fixtures and reduce upward blue light pollution. A local condominium association has asked for a redesign of their existing lights to match the mid-century modern aesthetics of their buildings. Several models were made for the community to vote on. Metal working, welding, and 3D printing were used to create the prototype light fixtures. Creo Parametric was used to create the final models as well as the 3D-printed light holder. The proposed light fixture uses a simple screw-in LED light bulb that provides 800 lumens and 2700 Kelvins of visible light, and complies with the International Dark Sky Association guidelines.
DIE RACKING SYSTEM SOLUTIONS FOR PROCESS TIME IMPROVEMENT
by: Tristan Bloomer, Nicholas Brookens, Blake Groves, Jared Heffelbower, Jeff Meldrum, and Patrick Shubnell
Sponsor: Amhawk Steel Fabrication, Inc., Regi Kurien, P.E.
Faculty Advisor: Timothy Greene, Ph.D.
9:00 a.m. to 9:25 a.m.
A local metal fabrication company was experiencing long changeover times in their press brake system, resulting from disorganized tooling, plant layout, and poor tool inventory. A time study was conducted and the plant layout was analyzed for potential non-value added time that could be eliminated from the process. New racks were designed and existing racks were reorganized to be placed in easily accessible locations. Following a tooling inventory audit, dies were identified by number and location, and then matched to specific racks in the shop. The new racking system was designed with the intent of lowering the average changeover time from 45 minutes to 15 minutes or less while promoting a safer work environment.
DIE CASTING IN A BOX 4.0
by: Daniel Niekrasz, Khoo Yee Keong, Van Mang, and William Mason
Sponsor: NADCA Chapter 3 and Visi-Trak
Faculty Advisor: Sam Ramrattan, Ph.D.
9:30 a.m. to 9:55 a.m.
Companies and educational institutions are looking for a miniaturized and mobile die caster to train students and employees on the operation of standardized casting technology. In order to make the die caster meet industry standards, an electrical enclosure was installed, electrical components were reworked, brackets were fabricated, a SolidWorks CAD model was generated, and an operations manual was created. Standardizing the machine included the use of tools such as SolidWorks, Gantt charts, fabrication tools, hydraulic schematics, and wiring diagrams. The completed project improved upon the learning material available to educate people on the die casting machinery that is currently used in industry.
THE FUTURE OF MOLD VENTING THROUGH METAL 3D PRINTING
by: Dillon Fort, Michael Francisco, Zachary Glascock, and Luis Hernandez
Sponsor: DENSO, Joseph Worden
Faculty Advisor: Jay Shoemaker
10:00 a.m. to 10:25 a.m.
The automotive injection molding industry is plagued with defects caused by the entrapment of volatiles. 3D-printed inserts with varied venting structures were created with the goal of alleviating these issues, as venting structures will help trapped gases escape injection molds. The types of ventable structures used were lattice structure, variable density, and vertical channels. Decision matrices were created to determine which venting structure best fit the specified criteria. Design and simulation software such as NX, Autodesk Netfabb, and Autodesk Moldflow were used to generate the product process and mold; and cost analysis and testing determined the best method of venting. Using the appropriate structure, companies will now be able to integrate this method of venting, which will lead to cost savings and the reduction of time and resources.
HYDRAULIC TRICYCLE FOR THE FLUID POWER VEHICLE CHALLENGE
by: Chris Frank, Eric Hudson, Chris Root, and Jason Topp
Sponsor: NFPA Education and Technology Foundation
Faculty Advisors: Alamgir Choudhury, Ph.D. and Jorge Rodriguez, Ph.D.
10:30 a.m. to 10:55 a.m.
This project team assembled and modified a tricycle to compete in the national Fluid Power Vehicle Challenge (FPVC) by increasing the vehicle’s propulsion through hydraulic power. After removing the standard chain and sprocket drivetrain, a tricycle was altered to incorporate a hydraulic-powered system with the goal of increasing energy output while decreasing rider work. Tasks that were completed included designing a fluid circuit, calculating component efficiencies, and establishing best-suited gear ratio between pump and motor, all while reducing vehicle weight. The completed hydraulic tricycle can serve as an economical and alternative method of transportation.
PORTABLE, ECO-FRIENDLY BOOT DRYING DEVICE
by: Emily Barshaw, Nathan Hurlbert, Pierce Lonsbery, and Marissa Poth-Miller
Sponsor: KMS Designs, Inc., Karen Smoots
Faculty Advisor: Jorge Rodriguez, Ph.D.
11:00 a.m. to 11:25 a.m.
Wet boots can cause a multitude of medical afflictions and can be difficult to dry outdoors with existing dryer options. Military personnel, outdoor workers, and nature enthusiasts will appreciate a portable, eco-friendly boot drying device. Standard military boots were methodically wetted, and a variety of available boot dryers were analyzed using a pitot tube and moisture meter to measure air velocity and moisture content within the boots. Following testing, CAD software was utilized to develop multiple models before finalizing the prototype design. Users will not have to cut their adventures short; this powerful device will dry their boots anywhere.
SCHEDULING FOR ASEPTIC MANUFACTURING OPERATIONS
by: Kristofer Green, Alexander Morris, Sydney Rearick, and Nicholas Vorac
Sponsor: Pfizer, Inc., Robyn Cornish
Faculty Advisors: David Lyth, Ph.D. and Balmatee Bidassie, Ph.D.
11:30 a.m. to 11:55 a.m.
A local pharmaceutical manufacturer is planning to expand their workforce with the addition of a new manufacturing line, raising concerns of overcrowding their aseptic gowning rooms. These gowning rooms are environments free of harmful bacteria and are a vital part of manufacturing pharmaceuticals; they are required by federal and international laws. Following data collection, simulations, and modeling, a new schedule was created to accommodate an influx of additional workers. Using Six Sigma, 5S, lean manufacturing, and the design process, the new schedule was finalized using ProModel. The updated scheduling affects the quality of life for workers as well as the productivity of the processing line.
SWING HINGE REDESIGN USING FRICTIONLESS BRAKING
by: Jake Clark, Matt Hensler, Adrian Torres, and Steffan Werth
Sponsor: Landscape Forms
Faculty Advisor: David Middleton, IDSA
1:00 p.m. to 1:25 p.m.
A local outdoor furniture manufacturer’s previously designed swing had been experiencing damaged components caused by misuse and over-extension of the swing radius. An redesign of the main hinge mechanism that controls the range of motion has been developed to replace the original design. Using the design process, computer-aided modeling software (SolidWorks) rendered brainstormed ideas into the final design. Finite element analysis (FEA) and physical testing were also used to analyze mechanical and material constraints. This newly engineered hinge extends the life of the product and protects it from any further misuse.
PROJECT MANAGEMENT AND PROCESS IMPROVEMENT FOR COMPLEX, LOW VOLUME MANUFACTURING
by: Joshua Bilski, Kevin Kuiper, Will Massey, Ben Sinclair, and Matt Tomkiel
Sponsor: Landscape Forms – Studio 431
Faculty Advisor: Larry Mallak, Ph.D.
1:30 p.m. to 1:55 p.m.
Developing a concrete, repeatable process is essential to a productive manufacturing system. Growth, coupled with increasing complexity, made timeline predictability and efficiency significantly more difficult for a manufacturer of custom outdoor environments. The project team deployed a blend of quantitative and qualitative techniques to improve the process. Working with designers, procurement, and manufacturing to obtain input, the team built a new process that is repeatable and allows for flexibility and predictability in complex projects.