Student presentations
Spring 2026
Session Chair: Dr. Tim Pasang and Dana Butt
Room D-201
Investigation of Impeller Housing Casting Defects
9 to 9:25 a.m.
Team Members:
Ashlee Tang
Brendan Edwards
Lily Kieliszewski
Jayson York
Sponsor:
Cooper Foundry
Faculty Advisor:
Dr. Robert Tuttle
Cooper Foundry, a local company in Kalamazoo, has encountered a high return rate of impeller (fluid pump) housings it produces due to casting defects. Detailed macro- and microscopic analyses were conducted on the parts to observe the defects and possible causes. Solidification simulations were initially performed to correlate with the defects, and then to predict possible solutions for defect elimination. The results of these simulations such as liquid fraction and anticipated porosity were analyzed to create the final process and design suggestions for reducing defects.
Investigation of Warpage with Anchor Points for Injection Molded Parts
9:30 to 9:55 a.m.
Team Members:
Cameron Smith
Asma Al-Gharib
Jarrod Patmore
Kris Vostal
Sponsor:
General Die & Engineering
Faculty Advisor:
Jay Shoemaker
Warpage for injection molded parts remains a prevalent challenge. To understand warpage behavior, Autodesk Moldflow Insight uses anchors with warpage results for consistent viewing of results between analyses. A six-cavity injection mold was designed and constructed to produce parts demonstrating how anchoring influences the perception of warpage. Autodesk Moldflow Insight was used to simulate the filling, cooling and warpage of the parts produced. Students and Moldflow users received a set of molded parts and a card describing the visual representation of warpage. The injection mold built also highlights the complexity and design challenges associated with a multi-cavity injection mold with non-flat parting lines.
Presentations will take place at Floyd Hall in room D-201.
Production Optimization of New Injection Molding Machine
9 to 9:25 a.m.
Team Members:
Darren Hiemstra
Landon Ackerson
Trevor Pilbeam
Joe Rogers
Sponsor:
Nissha Eimo Technologies
Faculty Advisors:
Jay Shoemaker
Dr. Sam Ramrattan
Western Michigan University’s College of Engineering and Applied Sciences received a new Milacron Roboshot 165-ton injection molding machine on a two-year consignment agreement. This project developed processes for the injection molding machine using various polymers to mold WMU Flying Disks. To develop these processes, rheology and gate freeze studies were completed. Weight, diameter and gloss measurements of the disks were analyzed to optimize machine parameters. In addition, an operating manual was produced to help future students understand the injection molding process and safely start up, run and shut down the Roboshot machine.
Calibration of a Solenoid-Driven Digital Impact Tester
9:30 to 9:55 a.m.
Team Members:
Alana Bell
Gabe Brown
Joe Funk
Faculty Advisor:
Dr. Sam Ramrattan
Dr. Alamgir Choudhury
Dr. Robert Makin
The casting industry has been using an antiquated impact test procedure for the last few decades. Modern times and safety measures have proved the Charpy Impact Test to be incompatible for the production floor due to a swinging arm hazard. To address this, a novel solenoid driven impact tester was designed and built to combat this concern. The enclosed compact semi-automated digital machine was calibrated to perform testing using AFS standardized disc-shaped sand specimens (50mm diameter by 8mm thick). These calibrations were compared to the results of the standard impact test and verified against theoretical calculations. Test results showed that there were no differences between the Charpy Impact Test and the solenoid driven impact tester.
Omni-Directional Material Handling Cart Enhancements
10 to 10:25 a.m.
Team Members:
McKinnley Mosher
Aiyaan Morshed
Luke Kelly
Anthony Fagaly
Sponsor:
Conceptual Innovations
Faculty Advisor:
Dr. Jorge Rodriguez
This Senior Design project focused on enhancing an Omni-Directional Material Handling Cart developed by Conceptual Innovations for warehouse applications. The cart was designed to transport heavy loads with high maneuverability, providing an efficient solution for industrial environments. To improve performance, the original 0.3-horsepower motors were replaced with 0.5-horsepower motors. Also, through motor housing modification, structural reinforcements increased the load capacity from 8,000 lbs. to 20,000 lbs. SolidWorks models and finite element analysis simulated stresses to guiding design decisions. A physical prototype incorporating the upgrades was manufactured to validate performance improvements.
Presentations will take place at Floyd Hall in room D-201. You can also watch via Webex (meeting number: 2868 776 6344 password: 2pqWUXM34mF).
Formula SAE EV: Topology Optimization of Motor and Differential Mounts
*This presentation will be taking place in room D-210 from 11:30 to 11:55 a.m. with the Department of Mechanical and Aerospace Engineering Section B.*
Team Members:
Xavier Berger
Adam Fischer
Aaron Warner
Sponsors:
WMU FSAE Bronco Racing
Melling Engineered Aluminum Castings
WMU Metal Casting Lab
Faculty Advisors:
Dr. Javier Montefort
Dr. Robert Tuttle
Improvements to the motor and differential mounts for the BR25-EV were made. These consisted of refining the current mounts to reduce weight while still fitting within the safety and packaging requirements. Topology optimization software utilized an iterative design process to identify designs from hardpoint, loading, and manufacturing constraints. Finite Element Analysis (FEA) validated that the final geometry withstands the simulated stresses. Casting solidification simulations were used to design a manufacturing process and minimize defects of the aluminum alloy mounts. Post machining was utilized to complete the parts. These processes achieve weight reduction while increasing the strength to maintain safety and performance standards.
Redesign and Manufacturing of an Injection Mold
9 to 9:25 a.m.
Team Members:
Tyler Flynn
Ethan Jack Boot
Chris Redder
Faculty Advisor:
Jay Shoemaker
A 2017 senior project of designing and building a six-cavity family injection mold was not completed. This project continued designing and manufactured the mold. The parts produced by the mold are used to demonstrate how an injection molding simulation software, Autodesk Moldflow, shows part warpage based on different anchoring locations on the part. The parts have complex shapes with curved parting lines requiring the part and mold designs to be modified to manufacture the mold with its complex geometry. The mold was built using computer numerical control machining centers, wire electrical discharge machining and manual machining. The mold also requires a hot runner to operate. To power the hot runner, a hot runner controller was re-wired to connect the mold to the hot runner controller. Parts were molded to validate the operation of the mold.
Design and Manufacturing of a Hydraulic Powered Vehicle
9:30 to 9:55 a.m.
Team Members:
Luis Molina Gonzalez
Nick Kotsonis
Jiivan Manoharan
Aman Panchal
Edward Prescott
Tiffany VanPeenen
Sponsor:
National Fluid Power Association
Faculty Advisors:
Dr. Matt Cavalli
Dr. Alamgir Choudhury
Dr. Jorge Rodriguez
The project goal was to build a competitive vehicle that is safe, functional, reliable and efficient. The project design guidelines were set by the National Fluid Power Association for the fluid powered vehicle challenge. The engineering design process was utilized for product development, implementation of computer aided drafting and testing fluid circuit designs. This project was a hands-on development experience that combined knowledge of physical product design and fluid power circuitry to create a complete project from start to finish. The vehicle created was based on a recumbent tricycle, modified to use hydraulic power to facilitate movement, and electrical power for controlling the hydraulic circuit.
Implementation of Robotics and Machine Vision in Tire/Wheel Assembly
10 to 10:25 a.m.
Team Member:
Marcus Henderson
Sponsor:
WMU Robotics Lab
Faculty Advisors:
Dr. Jim Burns
Dr. Lee Wells
This project focused on automating the assembly process for remote-controlled car tires and wheels using selective compliance assembly robot arm (SCARA) robotics and machine vision technology. The objective was to determine feasibility by integrating custom fixtures, robotics, and real-time quality control through vision systems. Key design aspects are custom fixtures for stability during assembly, the assembly strategy and the process sequence. The final system serves as a scalable model for similar automated assembly processes, reducing human error, increasing throughput and enhancing overall quality.
Evaluation of Modified Cone Jolt and Hot Friability Tests for Green Sand
10:30 to 10:55 a.m.
Team Member:
Brandon Smith
Sponsor:
WMU Metal Casting Lab
Faculty Advisor:
Dr. Sam Ramrattan
Testing and data collection on new systems of modified cone jolt test and hot friability test is done to evaluate tensile strength, stiffness, toughness, and erosion of green sand. Collected data shows that both tests measure differences in properties of green sand media. This testing at WMU is important for the creation of quality castings in green sand casting. Tests show that both processes can bring valuable differentiation in data that allow for green sand properties to be tested better than before.
Presentations will take place at Floyd Hall in room D-201. You can also watch via Webex (meeting number: 2636 691 0064 password: EDMMSbroncos).
Steel Test Castings for Machinability Studies
9 to 9:25 a.m.
Team Members:
Alex Waugh
Jamal Mitchel
Sponsor:
WMU Metal Casting Lab
Faculty Advisor:
Dr. Robert Tuttle
WMU’s casting laboratory lacked a standardized method of testing the machinability of new alloys. Extremely strong steels are useless if they cannot be manufactured into products. Standardized test castings for machinability studies were created in an effort to move manufacturing examination earlier in the alloy development process. By creating one casting geometry for milling and drilling, and one for turning, these castings now provide a way to properly analyze alloys on basic machine tools.
Design and Manufacturing of Rotational Molds for the WMU Plastics Processing Lab
9:30 to 9:55 a.m.
Team Members:
Allen Saunders
Annescia Rollins
Brett Sanders
Sponsor:
WMU Plastics Processing Lab
Faculty Advisor:
Jay Shoemaker
The rotational molds in WMU’s plastics lab were in a state of disrepair due to their heavy use over their many years in operation. This project revolves around the design and manufacturing of two new molds (a hockey puck & tree topper star), as well as their implementation into WMU’s engineering plastics courses. Along with the new molds, a re-worked rotational molding process was created on the use of the machines with their two new molds and optimized through research and continuous improvement. The new process and molds were introduced to the WMU’s engineering plastics lab, where a newly developed operation manual will give the students knowledge of the operation and maintenance needed for the lab’s rotational molding machines.
How Underflow and Weld Lines Affect the Strength of an Injection Molded Part
10 to 10:25 a.m.
Team Members:
Aidan Fayhee
Mitchell Griffeth
Justin Hoskins
Sponsor:
WMU Plastics Processing Lab
Faculty Advisor:
Jay Shoemaker
The presence of a weld line that could experience underflow can affect the strength of an injection molded part. By producing several different tensile test samples under the direction of a Design of Experiments (DOE), a determination of the part’s strength was made under different processing conditions. Comparing the results of ABS (Acrylonitrile Butadiene Styrene) and Noryl (10% glass filled polyphenylene ether (PPE) and polyamide (PA) blend) proved that weld lines experiencing underflow affect the strength of an injection molded part.
Presentations will take place at Floyd Hall in room D-201.