Presentations will take place at Floyd Hall in room D-109 on Dec. 8. 

Expanded Polypropylene Foam Densifier 

8 to 8:25 a.m.

Team Members: 
Bryce Kuhn
Lily Steele

Sponsors: 
Brant Deemter, Sebright Products
Loren Dykstra, Sebright Products

Faculty Advisor: 
Dr. Shrabanti Roy

Expanded Polypropylene (EPP) is used in modern packaging as a more robust alternative for Expanded Polystyrene (EPS). However, it cannot be recycled efficiently due to its strong shape memory properties. Through thermodynamic modelling and prototype testing, an efficient densification process that minimizes the amount of fumes, maximizes the densification ratio, and is cost-effective has been developed. An addition to an existing Expanded Polystyrene (EPS) densification machine from Sebright Products allows for a simpler and more efficient recycling of the materials that consumers can easily attach to their existing Polystyrene densification equipment.

Model G Air Separator Performance and Adjustability Redesign

8:30 to 8:55 a.m.

Team Members:
John Kinkema
Josie Morrow

Sponsor:
Trevor Thornton, PRAB

Faculty Advisor:
Dr. Shrabanti Roy

The Model G chip separator required improved adaptability to varying chip materials and geometries while protecting downstream equipment from damaging tramp metal. Autodesk Inventor, fluid mechanics principles and computational analysis were used to evaluate and redesign critical system components. Airflow adjustment methods were developed, transition chute vane geometry and placement were optimized for more uniform airflow, and sensor protection concepts were evaluated to reduce false faults caused by contamination. Engineering analysis, benchmarking, CAD modeling and design evaluation produced design recommendations that will likely improve separation consistency, operational flexibility and reliability while reducing the potential for equipment damage and unnecessary downtime.

Smart Enclosure Optimization

9:00 to 9:25 a.m.

Team Members:
Jake Lesher
Keilan Mccann
Zach Proeber

Sponsor:
Amit Jain, M.S.’03, Design Filtration Microzone Inc. 
Daxesh Patel, Design Filtration Microzone Inc.

Faculty Advisor:
Dr. Pnina Ari- Gur
Dr. Robert Makin

An IoT-based monitoring and control system is becoming the standard for all devices and therefore developing this system is critical for future sales. A prototype was developed to monitor environmental parameters such as temperature and humidity, while functions including supply airflow, LED lighting, UV lighting and sash or door status were controlled or indicated through a central PLC system. An interactive HMI was used to display operating conditions and provide basic control functions. Additional features such as alarms, emergency shut off and remote monitoring through mobile devices were also incorporated. The system is intended to provide a practical platform for environmental monitoring, equipment control and remote access.

Coast Guard Auxiliary Aviation Communication Interface

9:30 to 9:55 a.m.

Team Members:
Nic Buccilli
Ethan Cook
Lena Smith

Sponsors:
John Chapman, US Coast Guard Auxiliary 
Bob Brutvan, US Coast Guard Auxiliary
Ron Keil, US Coast Guard Auxiliary
Brian Dickover, US Coast Guard Auxiliary
Steve McCarty, US Coast Guard Auxiliary Division 33, Great Lakes District - West

Faculty Advisor:
Dr. Damon Miller

When conducting missions for the United States Coast Guard Auxiliary, volunteers must communicate with both air traffic control and maritime radio systems. Due to frequency differences, separate devices are required for each communication system, creating challenges for effective communication and situational awareness. To address this challenge, an external device was designed to combine the two communication signals and to allow the pilot and crew to select which signals to interface with using switches. The device connects directly to existing audio and microphone jacks typical in aircraft operated by Coast Guard Auxiliary volunteers. This system provides a seamless interface between volunteers and their respective radio communication systems.

Dispensing Kiosk Performance Optimization

10 to 10:25 a.m.

Team Members:
Bret Dykstra
Dan John Flynn 
Khang Le

Sponsors:
Megan Ford, Freeosk Inc.
Albert Kohn, Freeosk Inc.
Steve Koza, Freeosk Inc.
Jon Shoemaker, Freeosk Inc.

Faculty Advisors:
Dr. Dinesh Maddipatla 
Dr. Javier M Montefort-Sanchez

Any product is exposed to performance variation when in transit from the manufacturing site to its operating field. SolidWorks, a popular CAD modeling software, was utilized to create an injection-molded clamp to protect components from various shipment conditions. Finite Element Analysis and 3D printing were used to prototype the clamp’s effectiveness. In addition, to increase validation and efficiency of repairs, a statistical process control (SPC) was formulated to detect component failure before being sent to the operating field. The deliverables both improved the repairment process and reduced the uncertainty of shipment conditions.

Supersonic Fuel Distribution Wind Tunnel Test

10:30 to 10:55 a.m.

Team Members:
Andrew Abar 
Emily Holtz 
Yesenia Sanchez 
Tony Tharp-Baquedano

Faculty Advisor: 
Dr. Bade Shrestha

Access to large-scale supersonic facilities is costly and sometimes impractical for educational and research applications. A small-scale blow down supersonic wind tunnel was designed and built using existing equipment and materials. The settling chamber, nozzle and testing section designs were optimized using CFD simulations modeling velocity, pressure, and flow pattern. Manufacturing costs were reduced using 3-D printing parts. A compact blow-down supersonic wind tunnel provides a practical platform to conduct research and make measurements using Particle Image Velocimetry (PIV) techniques on mixing pattens of fuel and air at supersonic speeds. The results provided valuable insight into supersonic flow behavior and mixing pattens providing constructive guidance in improvement to supersonic aircraft and missiles and their propulsion systems design.

Wind Tunnel Airfoil Noise Reduction

11 to 11:25 a.m.

Team Members: 
Hanna Elias
Ivan Gonzalez
Emile Roedan

Faculty Advisor 
Dr. Bade Shrestha

Reducing airfoil noise was important because excessive aerodynamic noise can affect comfort, environmental quality, and the performance of systems that rely on smooth airflow. Different variations of the NACA 0012 airfoil were tested in an anechoic chamber and evaluated using noise and flow simulations in ANSYS Fluent. The results were compared to determine how changes in airfoil shape influenced airflow behavior, turbulence and sound levels. This work enabled us to identify designs with better potential to reduce noise while maintaining effective aerodynamic performance.

Minimizing Power Loss in a Diesel Particulate Filter System

11:30 to 11:55 a.m.

Team Members:
Aaron Schubkegel
Nathaniel Wilson

Faculty Advisor:
Dr. Bade Shrestha

Diesel particulate filters (DPFs) are required on modern diesel engines to meet EPA particulate matter standards. However, the DPF causes exhaust backpressure to build, reducing engine power and increasing fuel consumption. The scope of this design project was to assess creative solutions for reducing DPF exhaust backpressure. Using computational modeling and established DPF models, a novel solution was explored and analyzed. The resulting model provides a compliant path toward restoring diesel engine performance without sacrificing emissions control.

Optically Guided Fixed-Wing Autonomous Aerial System

1 to 1:25 p.m.

Team Members:
Michael Van Dorp
Austin Hoek

Faculty Advisor:
Dr. Matthew Cavalli

Recent world events have demonstrated the immediate need for low-cost, mobile, and self-contained UAV interception devices. A prototype aircraft was developed to test a novel control system that uses proportional-derivative image processing logic along with laser diffraction to spot and intercept lightweight aerial targets at visual ranges. This system is powered independently, is not susceptible to radio jamming, and can be deployed in a matter of minutes to add a layer of safety to protected low-altitude airspace. Additionally, this system functions with commercial off-the-shelf and additively manufactured hardware, which lowers the cost of engagement when compared to legacy anti-air solutions.

Hybrid Electronic-Mechanical Continuously Variable Transmission for Low Power Vehicles

1:30 to 1:55 p.m.

Team Members:  
Cristian Correa Carmona
Diego Corcuera 
Morgan Langhann

Faculty Advisor:
Dr. Matthew Cavalli

Mechanical continuously variable transmissions for small engines are reliable and lightweight but extremely challenging to fine-tune, requiring disassembly and the installation of new springs and weights installed to change the CVT performance. A hybrid electronic-mechanical Continuously Variable Transmission (HE-CVT) was designed using SolidWorks, precision-machined and assembled. The HE-CVT quickly allows specified modifications to a tuning curve that dictates the response rate of the CVT. The HE-CVT was programmed using an Arduino controller with a Hall effect sensor reading engine RPM to actuate the CVT along the entire RPM range. This hybrid approach eliminates manual clutch re-tuning downtime while reducing power consumption compared to a fully electronic CVT.

Bronco Baja Racing CVT Cooler System

2 to 2:25 p.m.

Team Members:
Sean Davis
Miles Evink 
Ryan Wehmeier

Sponsor: 
WMU Bronco Baja Racing

Faculty Advisor: 
Dr. Matt Cavalli

The CVT Cooler was designed for Bronco Baja Racing to improve vehicle performance and extend CVT belt life, reducing replacement costs for the team. The system uses ambient air and an inline fan to provide continuous cooling through the CVT case. A custom intake with an inline filter prevents particulate matter from entering the system. Thermal and performance modeling are used to evaluate operating temperatures, airflow, and overall cooling effectiveness. DFMA principles simplify fabrication and maintenance, while an adaptable design allows the system to support future Baja vehicles tuned for higher top speeds and more demanding conditions.

DMMI Static Alignment Jig for Evaporator Assembly

2:30 to 2:55 p.m.

Team Members: 
Erich Hebel
Aidan Halstead
Christopher Burdick

Faculty Advisor: 
Dr. Matthew Cavalli

DENSO Manufacturing Michigan Inc. formerly relied on manual machine changeover adjustments to maintain proper alignment of pneumatic cylinders used to assemble evaporator cores. These evaporator cores serve a critical role in vehicle HVAC units. Misalignment in the Y and Z directions can result in improperly positioned end caps and blocks, leading to rework, scrap, and production downtime of the evaporator cores. This project focused on developing a Static Alignment Jig to provide a quick and repeatable method for verifying cylinder alignment during machine changeovers. The implemented system used mating pin blocks mounted to the four pneumatic cylinders, and a jig base plate containing four corresponding alignment holes. When all four pins mated simultaneously, the machine was
confirmed to be properly aligned; failed mates identified the cylinder requiring adjustment. The project aimed to not only reduce down-time but also eliminate alignment-related assembly errors while providing operators with a simple, reliable verification method that could be integrated into the existing manufacturing process.

Temperature Compensation in Lathe Machining

3 to 3:25 p.m.

Team Members: 
Kendall Henderson 
Rachel Piechotte

Sponsor: 
Doug Montgomery, B.S.E.’14, Dauch Corporation

Faculty Advisor:
Dr. Richard Meyer

Automotive components can experience dimensional variation caused by temperature changes during manufacturing. These variations may lead to quality issues and increased scrap. An FEA analysis was completed to determine the effectiveness of using air circulation to cool components. This project focuses on developing a method to monitor component temperature and automatically adjust process parameters to compensate for temperature-related variation.  Additional process controls will be evaluated to improve temperature consistency between manufacturing operations. The goal is to improve process stability, product quality and manufacturing efficiency while reducing scrap.

Implementation of Parker Pneumatic Test Stand in the Motion and Controls Laboratory

3:30 to 3:55 p.m.

Team Members: 
Alan Darwesh 
Alex Leonard

Sponsors: 
Nicholas Larsen, B.S.E.’11, M.S.E.’21, Parker Hannifin
Robert Buerkel, Parker Hannifin

Faculty Advisor: 
Dr. Richard Meyer 

The Parker Motion and Controls Laboratory lacks dedicated equipment for pneumatic systems instruction and experimentation. This project involved the design, fabrication and implementation of a Parker pneumatic test stand featuring two proportional-integral-derivative (PID) controlled experiments.  A programmable logic controller (PLC), sensors and Parker pneumatic components were integrated to demonstrate closed-loop control principles. The completed stand includes a pneumatically actuated seesaw for position control of a ball and an airflow-based system for ball height control. This pneumatic test stand provides a platform for hands on instruction in pneumatics, automation and control systems.

Modular Wheelchair Joysticks

4 to 4:25 p.m.

Team Members:
Riley Creen
Bridget Lundy

Faculty Advisors:
Cayce Kahrl
Peter Gustafson

Electric wheelchairs have many customizations to suit the users’ needs except for the joystick handle. A modular set of joystick handles was created to be used on electric wheelchairs that can be 3D printed and easily switched out using a common base. This allows users to be able to fully customize the handle based on ability level and need at that time. Including raising or lowering the joystick using spacers and changing how the hand rests on the handle using different joystick designs. The handles have available shapes beyond what is currently offered by aftermarket companies. The handles were tested using volunteers from a local power soccer team.

Virtual Torque Sensor: Engine Simulation and Testing

4:30 to 4:55 p.m. (CLOSED to the public)

Team Members:
Torrey Cookman
Osman Omer 
Samuel Schnepp

Sponsor:
Virtual Torque Sense LLC

Industry Mentor: 
Vivek Iddum, M.S.E.’18, Ph.D.’25

Faculty Advisor:
Dr. Muralidhar Ghantasala 
Dheeraj Velamala

Optimizing commercial vehicle gear shifts requires precise, real-time engine torque measurements, yet conventional physical sensors remain cost-prohibitive and difficult to integrate into existing drivetrains. A third-generation virtual torque sensor was implemented and validated as a practical alternative. The system paired a magnetic flywheel speed sensor with vehicle CAN bus telemetry, using driveshaft strain gauges for physical validation. Complementary virtual engine simulations will generate datasets across varied loading scenarios. Training computational models on experimental measurements and simulated datasets will yield a robust, adaptable torque estimator capable of maintaining strong correlation across diverse heavy-duty duty cycles.

Presentations will take place at Floyd Hall in room D-115. 

Small Plasma Assembly for a Replaceable Cathode (S.P.A.R.C.) 

9 to 9:25 a.m.

Team Members:
Derek Martindell 
Zach Van Sweden 
Drew Rais 
Nate Geskes

Faculty Advisor:
Dr. Kristina Lemmer

Specific electric spacecraft thrusters require cathodes to operate, and each thruster will require a different power output from its cathode. A cathode was created to fill the role of a low power emission cathode. Additionally, the cathode was designed to allow the disassembly and replacement of parts. This replaceability allows the components to vary in geometry. This variation ability turns this cathode into a future experimental platform. By changing the inner diameter of the cathode orifice, keeper orifice and the distance between the orifices, the effects can be studied to find the optimal geometries and dimensions for low powered cathodes.

Development of a Cost-Effective, Gridded Radio Frequency Ion Thruster, Small (GRITS)

9:30 to 9:55 a.m.

Team Members:
Cody Joiner
Eric Olsen
Yash Patel
Johnathan Quiroz

Faculty Advisor:
Dr. Kristina Lemmer

Affordable ion propulsion hardware suitable for educational laboratories was needed due to the cost, size, and complexity of conventional ion thrusters. This challenge was addressed by redesigning a cathodeless gridded radio-frequency (RF) ion thruster to improve RF coupling efficiency, plasma stability, and reduce power losses. The work involved computational plasma modeling in COMSOL, mechanical
redesign of the discharge chamber, and construction of an L-type RF matching network, with design parameters verified using vector network and VSWR analyzers prior to plasma operation. Engineering activities included coil optimization, grid alignment and refinement, and impedance tuning at an operating frequency of 13.56 MHz. The resulting system provides a practical and modular platform that can be used for educational exploration of electric propulsion concepts and hands-on laboratory experiments.

Electrospray Retarding Potential Analyzer (RPA)

10 to 10:25 a.m.

Team Members:
Ben Miller 
Sang Yeon Chung 
Zahirah Alshehri

Faculty Advisor:
Dr. Kristina Lemmer

Electrospray thrusters are a newer type of electric propulsion that can produce very small, well-controlled thrust for small spacecraft. To understand how well they work, we need good diagnostics to measure what’s coming out of the plume. This senior design project is focused on designing and building a Retarding Potential Analyzer (RPA) that can be used with an electrospray propulsion test setup. The goal of the RPA is to measure key plume properties, including ion energy distribution and beam current. These measurements help us evaluate thruster efficiency, study how the propellant breaks apart (fragmentation), and compare experimental results to propulsion models. Our RPA uses a multi-grid design. By applying and sweeping a retarding voltage, the device blocks ions below a certain energy while allowing higher energy ions through. We measure the collected current during the voltage sweep, and from that we can determine the energy profile of the beam. The design is being developed to work reliably in a vacuum environment and to integrate with existing lab electrospray test facilities. Overall, this project combines electric propulsion, plasma/beam measurement methods, instrumentation and data analysis to provide better experimental data for electrospray thruster development.

Micro Autonomous Drone System

10:30 to 10:55 a.m.

Team Members:  
Randi Anderson
Cari Ingram
Gabriel Williams

Faculty Advisor: 
Dr. Richard Meyer

Engineering courses, particularly Control Systems, often lack real-world experiences to effectively illustrate theoretical concepts. To address this gap, a hands-on drone flight system was developed to demonstrate important concepts like feedback control. Multiple drone configurations that simulate a space rocket were modeled in SolidWorks, 3D printed and assembled. The system was programmed through the Arduino IDE and incorporated LiDAR sensing for real-time altitude feedback. The final interactive platform reinforces theoretical control concepts, like stability and feedback, by exposing them to the thrill of real-world control implementations, further supporting growth in an educational environment.

Design and Optimization of the Solar Car Aeroshell

11 to 11:25 a.m.

Team Members:
Seth Carter
Logan Tipton
Samantha Usher

Faculty Advisors:
Dr. Peter Gustafson
Dr. Shrabanti Roy

The speed and efficiency of a solar car rely significantly on the aerodynamic body of the vehicle called an aeroshell. WMU’s Sunseeker solar car required a larger aeroshell to maximize solar panel array area while minimizing drag and weight. The geometry was designed in NX and optimized using computational fluid dynamic simulations in Ansys Fluent. Composite shell structural performance was evaluated through finite element analysis in Ansys Mechanical. Physical testing was done in a wind tunnel with application of Global Luminescent Oil-Film (GLOF) and composite panel destructive analysis further validating simulation predictions, ensuring aerodynamic and structural requirements are met.  

Aerodynamic Noise Reduction of Wind Turbine Blades 

11:30 to 11:55 p.m.

Team Members:
Grace Anderson
Phil George 
Abel Ramos
Itzel Sosa

Faculty Advisors:
Rishav Mishra
Dr. Bade Shrestha

This project investigated strategies to reduce aerodynamic noise from wind turbine blades by modifying the geometry and surface properties of a baseline NACA 0012 airfoil. Because turbine noise constrained modern wind projects, six modified configurations and smooth control were evaluated. All models were 3D printed with identical chords and span and tested in Western Michigan University’s anechoic wind tunnel under consistent operating conditions across a range of angles of attack. Sound pressure levels and spectra were measured using a fixed microphone position. Complementary Ansys Fluent simulations provided lift/drag coefficients, surface pressure distributions and near-wake flow fields. A decision matrix ranked concepts by noise reduction, manufacturability and cost.

Design and Validation of a Generic Le Mans Vehicle for Aerodynamic Research

1 to 1:25 p.m.

Team Members:  
Diego Rodriguez Gonzalez
William Lithgow Jimenez
Chantal Valenzuela Santana

Faculty Advisors:  
Thinnesh Ragupathy
Dr. Tianshu Liu

A standardized, open-source aerodynamic reference model of a Le Mans Prototype 2 (LMP2) vehicle was developed to address the lack of publicly available geometries suitable for high-performance automotive research. A fully parametric 1: 10 scale model based on FIA technical regulations and common homologated chassis features was designed to support modular testing of key aerodynamic elements, including the diffuser and rear wing. Because Reynolds number similarity could not be achieved at scale, the study emphasized flow-field topology, focusing on the interaction between the diffuser and the rear wing. CFD simulations supported wind tunnel experiments using PIV and GLOF techniques.

Autonomous Vehicle System Integration—Fusion and Navigation 

1:30 to 1:55 p.m.

Team Members:
Chris Bigelow
Jacob Haller
Jacob Huber

Sponsor:
Autonomous Vehicle Club, Western Michigan University

Faculty Advisor:
Dr. Zachary Asher

Autonomous ground vehicles are increasingly important in modern robotics, with applications ranging from transportation to industrial automation. This project focused on the development of an autonomous ground vehicle for the Intelligent Ground Vehicle Competition (IGVC). The primary objective was to convert an electric wheelchair into a fully autonomous platform capable of navigating outdoor courses while detecting obstacles, following lane markings, and reaching designated waypoints. An engineering analysis was conducted to determine the best methods for sensor integration, mechanical mounting, and navigation control while meeting all IGVC safety and performance requirements.

The following two presentations will be presented with the Department of Computer Science session held in room D-202

Autonomous Vehicle Perception and Control for IGVC 2026

Time: 11:30 to 11:55 a.m.
Room: D-202

Team Members:
Jack Herrington
Graham Rais
Carrasco Nbunh
Ebisa Bunti
Nicholas Vreeland

Sponsor:
Dr. Zachary Asher, Revision Autonomy

Faculty Advisors:
Dr. Zachary Asher
Dr. Wuwei Shen

In today's constantly evolving world, autonomous vehicles are becoming more common place. To address this, we are building an autonomous ground vehicle based on a donated electric wheelchair to compete in The Intelligent Ground Vehicle Competition (IGVC) in June 2026. The project has been developed using ROS2, Python, and C++. This project was split into two multidisciplinary teams of ME and CS students. Our responsibility is to handle perception and controls, including provisioning the lidar and camera to function as sensors for navigational data and implementing control algorithms for the vehicle to move. We were working with another Senior Design Group that will be responsible for navigation and sensor fusion. With our combined efforts we aimed to create a fully functional self-driving vehicle with the ability to sense its surroundings and intelligently plan a path forward.

3D Mapping of WMU Main Campus and Route Generation for Autonomous Vehicles

Time: 1 to 1:25 p.m.
Room: D-202

Team Members:
Aaron Charnas
Shannon Giberson
Mauricio Mancera-Bohorquez
Jonah Parker

Sponsor:
Dr. Zachary Asher, Revision Autonomy

Faculty Advisor:
Dr. Zachary Asher

Autonomous vehicles require reliable route planning and obstacle detection capabilities. Western Michigan University’s (WMU) Disability Services for Students (DSS) offers a vehicle for student transportation, which, while not autonomous, was developed to emulate an autonomous vehicle framework. A high-fidelity map of WMU’s main campus was created for use by this vehicle and was integrated into a ROS2-based visualization and routing framework. OpenStreetMap data, refined through on-site measurements, supported generation of a Lanelet2 map for localization, routing, and planning. Autoware tools enabled conversion and visualization in RViz, overlaying GPS tracking, LiDAR point clouds, routes, detected objects, and object trajectories. Recorded LiDAR, GPS, and IMU data were replayed using ROS bags to validate map and routing accuracy. This mapping and real-time visualization system provides a foundation for future navigation assistance research.

Session Chairs: Drs. Claudia Fajardo and Dan Kujawski
Room D-210

Enhanced Safety for Vertical Lift Door Locking Mechanism

9 to 9:25 a.m.

Team Members:
Philip Gryder
Benjamin Tiemeyer
Nate Woloszyk

Sponsor:
Joseph Jackson, Lindberg/MPH

Faculty Advisor:
Dr. Jinseok Kim

Industrial furnaces with vertical lift doors required a safer locking system that eliminated ladder use. Existing designs forced operators to access elevated locking pins, creating significant fall hazards during maintenance and loading operations. A ground-operated mechanical locking mechanism was developed to provide a positive mechanical stop capable of supporting the full static door load with an appropriate safety factor. Engineering efforts included mechanical design, material selection, ergonomic analysis, parametric 3D modeling and finite element analysis. Prototypes were fabricated and evaluated for reliability, durability and ease of operation, improving operator safety and long-term usability in industrial environments.

Optimized Hydraulic Valve Manifold Design

9:30 to 9:55 a.m.

Team Members:
Lane Adams
Ella Dill
Amanda Glanton
Jason Moreau
Gabriel Spees

Sponsors:
Chris Dykstra, Parker Hannifin
Julian Voss, Parker Hannifin
Diego Camiro, Parker Hannifin
Brad Craig, B.S.E.’09, Parker Hannifin 
Daniel Capozello, B.S.E.’22, M.S.’25, Parker Hannifin

Faculty Advisor:
Dr. Javier Montefort

Most hydraulic valve manifolds that were being used at Parker Hannifin were heavy and required external plumbing, while other lightweight designs were experiencing corrosion over time. Single-stage and dual-stage hydraulic valve manifolds are designed to support high-cycle hydraulic pump testing. This involves repeated loading and unloading with pressures reaching 5,000 psi. Extensive testing on these pumps are required to ensure longevity and aircraft safety while in use. The work included studying the requirements, designing 3D CAD models, creating detailed drawings and selecting the correct material for infinite fatigue life. Structural finite element analysis and internal fluid flow analysis were performed using simulation tools to evaluate stress, fatigue behavior, and pressure losses. The resulting designs reduced weight, eliminated external plumbing, increased corrosion resistance and improved long-term reliability for demanding hydraulic test environments.

Design and Fabrication of Rapid Prototyping Mold Tool

10 to 10:25 a.m.

Team Members:
Shekinah Mbwambo
Massimo Piccione
Dan Vanharmelen

Sponsor: 
Erik Myklebust, Vibracoustic

Faculty Advisors:
Dr. Javier Montefort
Jay Shoemaker

Long lead times and high costs made it difficult to quickly create prototype parts used in automotive rubber mounting applications. A new mold insert system was developed to allow fast creation of prototype parts using 3D-printed plastic components. These printed components were designed to withstand the heat and pressure of the injection molding process and fit into existing manufacturing equipment. Material selection, computer modeling and prototype testing were used to verify performance under operating conditions. The final design reduced prototype lead time from several weeks to one day, lowered tooling costs and increased flexibility during early stages of product development.

Energy Absorbing 3D-Printed Football Helmet for Safer Play

10:30 to 10:55 a.m.

Team Members:
Molly Blanchard
Evan Swank
Mason Thomas

Faculty Advisor:
Dr. Pnina Ari-Gur

Football helmets are designed to protect athletes’ heads, yet concussions remain a serious concern due to repeated high-impact collisions. This project developed and tested new ways to improve helmet safety by combining computer-based design, advanced 3D printing and standardized impact testing. Super-elastic materials were integrated into 3D-printed polycarbonate helmet structures to better absorb and dissipate impact energy. Controlled drop tests were used to compare different designs and evaluate their ability to reduce acceleration during impacts. By evaluating multiple design approaches for strength, weight and repeatability, this work contributes to safer, more effective helmet technologies for future athletes.

Validation of a Generic Formula 1 Vehicle for Aerodynamic Research

11 to 11:25 a.m.

Team Members: 
Preston Brockett
Dan Praise
Hung Quy Tran
Ethan VanTil

Sponsors:
Dr. Tianshu Liu, Optical Flow Dynamics LLC
Brian Montgomery, Optical Flow Dynamics LLC

Faculty Advisor: 
Dr. Tianshu Liu

Accurate measurement of surface skin friction and flow behavior remains a critical challenge in aerodynamic research and Computational Fluid Dynamics (CFD) validation. This project addresses that need by applying the Global Luminescent Oil Film (GLOF) technique to a generic Formula 1 vehicle in a controlled wind tunnel environment. The high resolution and global measurement of skin friction that the GLOF technique provides make it possible to improve accuracy and precision in Aerodynamics study. The resulting dataset will provide detailed experimental data for advancing aerodynamic understanding relevant to Formula 1 and other high-performance vehicles.

Design of Hydraulic Powered Bike for Fluid Power Vehicle Challenge

11:30 to 11:55 p.m.

Team Members: 
Dylan Chesebro
Zack Cummings
Isaac Premer

Sponsor: 
National Fluid Power Association

Faculty Advisors: 
Dr. Alamgir Choudhury
Dr. Jorge Rodriguez

The Fluid Power Vehicle Challenge (FPVC) is a competition in which teams design and race hydraulic powered vehicles. A recumbent bike was designed that uses a custom drivetrain, hydraulic system and user interface to achieve motion. The drivetrain was developed through analysis of vehicle kinematics, dynamics and human power limits. The hydraulic circuit was designed and simulated in Automation Studio; simulations were used to validate hydraulic modes and predict race performance. A regenerative brake system and Arduino-controlled manifold were simulated in LT-Spice, a circuit analysis software. The final bike exemplifies the challenge of developing an efficient, human-driven hydraulic vehicle.

Rocketry Airbrakes for Altitude Control

1 to 1:25 p.m.

Team Members:
Tyler Clendenning
Johnbosco Nguyen
Alex VunCannon

Sponsor:
AIAA Pegasus Chapter

Faculty Advisor:
Dr. Kapseong Ro

Solid rocket motors exhibit inherent thrust and burn variability, which complicates precise apogee targeting. In the NASA Student Launch Initiative (USLI), teams are evaluated based on their ability to reach a predetermined target apogee, requiring effective compensation strategies to reduce trajectory uncertainty. To address this challenge, a deployable airbrake mechanism was developed to modulate aerodynamic drag during ascent. Both passive deployment and active feedback control approaches were investigated through numerical simulation. Subsequent flight testing, supported by onboard sensor measurements, enabled real-time apogee estimation and trajectory regulation while also assessing the controllability, reliability, and practical feasibility of each method for future implementation on WMU USLI vehicles.

Portable On-Location Active Refrigeration and lntercooling System (POLARIS)

1:30 to 1:55 p.m.

Team Members:
Logan Szymanski
Arya Pandit
Nick Powers 
Ethan Truong

Sponsor:
Christopher Dykstra, Parker Hannifin

Faculty Advisor:
Dr. Christopher Cho

Qualification testing at the Parker Hannifin facility previously required over six hours to cool hydraulic fluid to -65°F, limiting testing productivity. This project developed a vertical mobile heat exchanger capable of reaching the target temperature in approximately one hour, providing faster cooling, improved temperature control and easy integration across test labs to reduce preparation time and increase testing efficiency.

Space-Degradable Explosive Bolt

2 to 2:25 p.m.

Team Members: 
Jonathan Baker
Markus Vanderzwaag
Garrison York

Faculty Advisor:
Dr. Tom Heine

Space debris poses an escalating threat to spacecraft and satellites as non-degradable hardware accumulates in LEO. This project developed an explosive bolt system using materials that degrade under LEO's unique conditions of elevated radiation, atomic oxygen, and atomic nitrogen. UV radiation spectrum testing confirmed degradation properties. Using CAD, FEA and fragmentation software, the bolt was engineered to withstand compressive and tensile forces up to one million pounds. Predictive models estimated orbital and material decay timelines, while scaling laws enabled mission-specific sizing. This degradable explosive bolt directly addresses space debris reduction by reducing continuing post-mission debris in Earth’s orbit.

Session Chairs: Drs. Muralidhar Ghantasala and Richard Meyer

Presentations will take place at Floyd Hall in room D-109.

Design and Thermal Optimization of an Airflow System for Western Michigan University’s FSAE Accumulator

9 to 9:25 a.m.
 
Team Members: 
Ben Favreau
Jack Quinn
Miranda Solecki
 
Faculty Advisor: 
Dr. Shrabanti Roy

A thermal management system is required in Formula SAE electric vehicles to avoid excessive heat buildup in lithium-ion batteries. A fan-assisted airflow system was developed with 3D printed ductwork integrated into a steel casing for Molicel P45B cells. Airflow distribution was modeled in Ansys Fluent where duct geometry and fan placement were designed to achieve uniform cooling. The final design provides consistent thermal performance while eliminating the mass penalties and leakage risks associated with liquid cooling systems.

Unmanned Aircraft Navigation in Urban Environments

9:30 a.m. to 9:55 a.m.

Team Members:
Ian Frederiksen
Garrett Hendon 
Saleh Saeed

Faculty Advisor:
Dr. Yrithu Pillay

Unmanned Aerial Vehicles can be used to assist emergency response by rapidly arriving and surveying the situation. Fixed-wing aircraft are faster and have higher endurance than multi-rotor UAVs. Flying a fixed-wing aircraft at low altitudes in urban environments necessitates quick reactions and optimized maneuvers to avoid obstacles. An autonomous, intelligent controller was designed to provide flight control in urban environments. MATLAB and Simulink are used to simulate trajectory planning to generate a path within the constraints of the aircraft’s dynamics. The proposed controller can plan maneuvers in a randomized obstacle field that simulates unpredictable urban environments.

Design, Analysis and Testing of a Prerunner 4-Link Suspension Lower Trailing Arm

10 to 10:25 a.m.

Team Members:
Jesse Hunt
Jared Lubieniecki

Sponsors:
Lenger Racing

Faculty Advisor:
Dr. Matthew Cavalli

A prerunner lower trailing arm is responsible for carrying the rear weight of an off-road vehicle while constraining the rear axle throughout suspension travel. These components are heavy, expensive and difficult to manufacture. A refined trailing arm design was developed. Forces exerted on a lower trailing arm have been evaluated through both hand and FEA methods. A new trailing arm has been designed to efficiently balance weight, cost and manufacturability. A complete parametric model has been created in SolidWorks, enabling evaluation across multiple configurations. The final design offers a lightweight, efficient and high-performance solution for advanced off-road suspension systems.

3D-Printed Supersonic Wind Tunnel

10:30 to 10:55 a.m.

Team Members:
Connor Faur
Harrison Scalf

Faculty Advisors:
Dr. Tianshu Liu
Dr. David Salazar

Supersonic wind tunnels help visualize the flow properties and shockwave formations around high-speed aircraft components. A computational fluid dynamics analysis was performed with Fluent to determine the required inlet pressure and optimal tunnel geometry, particularly with the nozzle to prevent underexpanded or overexpanded flow. Desired tunnel parameters were modeled in AutoCAD and 3D-printed with resin. Compressed air provides air flow to the inlet of the tunnel and exits the tunnel to the atmosphere. 3D-printing allows for simplistic modification and remains far more cost efficient compared to other materials.

Elevation of Fillers Over Standard Design Height

11 to 11:25 a.m.

Team Members: 
Jared Newland
Brendan Matthews

Faculty Advisor: 
Dr. Jinseok Kim

Package filling machines are the cornerstone of a food plant’s ability to meet production needs, and the ability to easily install, clean and maintain these machines is vital. To ensure these needs are met, a leg extension to raise the fillers over the standard design height was designed and tested in AutoCAD to withstand the maximum dynamic load on both level and sloped surfaces. The completed design allows for the installation of new fillers without modifying current plant conditions, including drain locations, water lines and conveyor height, while also maintaining the floor clearance of older models to minimize loss of access for staff.

Implementation of a Saw Stopping Mechanism for a Circular Saw

11:30 to 11:55 a.m.

Team Members:
Cameron Brown
Brian Crofoot
Jonathan DeVries

Faculty Advisor:
Dr. Matthew Cavalli

Handheld circular saws are among the most widely used power tools in construction and woodworking, but they are responsible for nearly 40,000 injuries each year. Unlike table saws, which have advanced safety systems, portable saws lack comparable protection. This project addresses that gap by developing mechanical design concepts for a blade-stopping safety feature. Through research, design modeling and analysis, this project explores practical solutions that could significantly enhance the safety of handheld saws and help advance future injury prevention technology in everyday power tools.

Intuitive, Comfortable and Secure Phone-to-Instrument Lyre Attachment Design

1 to 1:25 p.m.

Team Members:
Jeremy Hoerauf
Christopher Oberheim
Isaiah Zebrowski

Faculty Advisor:
Dr. Javier Montefort-Sanchez

In marching band, lyres are devices used to attach sheet music to an instrument, allowing the user to read their music while in motion. Recently, this sheet music has been replaced by cell phones. The lyres currently used by most collegiate marching bands have several problems, including unintuitive designs, unstable connections, weak materials and uncomfortable features for those attaching directly to the user’s arm. In order for these lyres to not impede the user’s ability to perform the rigid motions required when marching, new designs have been developed that are easy to understand, comfortable to wear and stable. A new phone attachment has been designed that connects to the three new designs: securing to either a metal clip, the bell of a trumpet or trombone, or the left forearm. These redesigns are tested side-by-side with the benchmark lyres during the regular season rehearsals of the Bronco Marching Band.

Shaving Reduction in Compressor Housings

1:30 to 1:55 p.m.

Team Members:  
Madelyn Reurink
Marshall Hoard
Alex Hearn

Sponsor:  
Michigan Automotive Compressor, Inc.

Faculty Advisor:  
Dr. Parviz Merati

Residual shavings left behind in machined compressor housings can lead to assembly issues and faulty compressors. A flow analysis was performed to determine areas of concern with flow circulation. A testing device was designed to model manufacturing equipment allowing the testing of a variety of nozzle designs with the purpose of improving the performance of the washing system. The test bench allows for the variation of flow characteristics and points of contact between the washer fluid and faces of the compressor housing. Based on the results from the various nozzle designs the most effective solution to completely remove residual shavings was determined. The final nozzle design improved the quality of outgoing compressors.

Improving Indoor Air Quality of Natatoriums

2 to 2:25 p.m.

Team Members:
Jacob Collins 
Shea McCarty
Alex Morrison
Joel Parker

Sponsors:
TowerPinkster

Faculty Advisor:
Dr. Christopher Cho

Many natatoriums experience poor indoor air quality, poorly regulated humidity levels and uncomfortable temperatures. These flaws lead to inadequate occupant comfort, negative health effects, facility deterioration and increased operational costs. Revit was used to design and model a heating, ventilating and air conditioning system that successfully manages the design challenges of a natatorium. By following ASHRAE guidelines and utilizing equipment to improve indoor air quality, the completed design demonstrates best practices for future aquatic facilities.

Wind Turbine Noise Reduction

2:30 to 2:55 p.m.

Team Members: 
Nour Badran 
Daniel Frey
David VanderKamp

Faculty Advisors: 
Rishav Mishra
Dr. Bade Shrestha

The NACA 0012 is a commonly used airfoil for wind turbine applications. When the baseline airfoil experiences turbulence, it generates acoustic noise that causes disturbance and irritation to nearby communities. Channel configurations and designs were developed for the airfoil to reduce turbulence and noise. Designs were modeled using SolidWorks and tested inside an anechoic wind tunnel chamber to record acoustic data. ANSYS Fluent was used to visualize fluid flow and make correlations between the trailing edge of the airfoil and turbulence generated. By utilizing Machine Learning, the best designs and channel configurations for the airfoil were inferred by the program.

Design of a Krypton Fueled, Magnetically Shielded, Low-Power Hall Effect Thruster

3 to 3:25 p.m.

Team Members: 
Renee Cilluffo 
Stephen Foster 
Grace Klang

Faculty Advisor: 
Dr. Kristina Lemmer

Hall effect thrusters (HETs) are currently the most prevalent form of electric propulsion (EP), a field of in-space propulsion systems that uses electricity to accelerate a gaseous propellant through electrical and magnetic means. An exploratory low-power, magnetically shielded HET has been designed to run on krypton propellent, significantly reducing the cost of flight compared to Xenon alternatives. The design has undergone numerous magnetic field and thermal studies via COMSOL Multiphysics, and anode development via Ansys CFD Software. Advancing EP technologies significantly increases the efficiency and capability of spacecraft, enabling them to travel faster, reduce fuel consumption and extend mission durations.

Session Chairs: Drs. Parviz Merati and Richard Meyer

Presentations will take place at Floyd Hall in room D-109.

Ionic Wind Airship

8:30 to 8:55 a.m.

Team Members:
Ramon Gabriel 
Medina Contreras
Nathanial Olechowski

Faculty Advisor:
Dr. William Liou

This project was dedicated to the development of an innovative ionic wind propulsion system for an airship, providing an alternative to traditional combustion engine systems. Unlike conventional propulsion methods that relied on fuel combustion, this thruster operated by generating airflow through the ionization of air particles using high-voltage electricity, creating a source of thrust. The primary objective of the project was to design, develop and optimize the ionic thruster system while ensuring its seamless integration with an airship platform. The modeling phase of the thruster was successfully accomplished, laying the foundation for further experimental validation. The airship itself was engineered with a focus on lightweight construction, ensuring efficiency and suitability for flight while maintaining structural integrity. Special attention was given to safety considerations, particularly in handling high-voltage equipment, to ensure the airship’s reliability and security in various environments. Beyond propulsion advancements, this project aimed to revolutionize airship design by addressing environmental and noise pollution concerns. By leveraging renewable energy sources to power the ionic thruster, the system provided a sustainable and eco-friendly alternative to traditional airship propulsion.

GoAERO Emergency Response Flyer 

9 to 9:25 a.m.

Team Members:
Dereck Baker 
Eliza Eaton 
Gavin Kubiak 
Alex Scholten

Faculty Advisor:
Dr. Peter Gustafson

GoAERO (a Boeing creation competition) aims to save lives by providing first responders with the first autonomous Emergency Response Flyer. Emergencies often escalate due to limited access to hazardous areas and ambulance dead zones; this compact flyer is engineered to enhance emergency response capabilities and cut down on crucial lifesaving seconds. Ensuring the swift transport of people or medical supplies in and out of critical areas, ultimately reducing risk and fatalities in crisis situations. Using CAD and simulation software, a scale model was evaluated under various conditions. Utilizing various resources at WMU’s College of Engineering and Applied Sciences, a viable scale model was fabricated. This model was used to showcase the flyers capabilities in a controlled environment and give supporting data on what a full-scale model could contribute to emergency response.

Baro-Inertial Measurement System for Aircraft 

9:30 to 9:55 a.m.

Team Members:
Jacob Donaldson 
Jonathan Nicolas Girier-Dufournier 
Cristian Sanchez
Russell Shutes

Sponsors:
Jay Crossman, L3 Harris Technologies
Paul Voisin, L3 Harris Aviation Systems
David Haaland, L3 Harris Aviation Systems

Faculty Advisor:
Dr. Peter Gustafson

Aircraft altitude and vertical velocity are critical flight characteristics for the pilot and the accuracy and reliability of those measurements are paramount. Baro-inertial measurement of these characteristics improve the possible accuracy of the system without the use of global navigation satellite systems (GNSS). An implementation of an algorithm for baro-inertial measurement systems was created. The instrument was constructed from off-the-shelf components and test flown. Performance of the system was analyzed for systemic errors, improved and reflown. The instrument can be used to study performance of baro-inertial measurement algorithms to improve current implementations. Construction and operation are fully documented to aid future development. 

Fuel Cell Powered Car 

10 to 10:25 a.m.

Team Members:
Ali Al Wahaibi 
Sameer Wasid 
Tanner Corstange

Faculty Advisor:
Dr. Bade Shrestha

As oil prices continue to rise and the demand for sustainable energy solutions increases, the development of alternative fuel technologies becomes more critical. This project focuses on harnessing the potential of fuel cells to power vehicles, specifically a golf cart, using a 1.2kW fuel cell. The project involved manually supplying hydrogen to the fuel cell and designing custom mounts and shafts to integrate an electric motor and differential into the system. Extensive testing was conducted on key components such as the compressor and motor to ensure optimal performance and reliability. This model presents a promising step toward reducing reliance on fossil fuels while advancing clean energy technologies.

Air Supply for Supersonic Research 

10:30 to 10:55 a.m.

Team Members:  
Hayden Clark
Patrick Requeno
Dylan Smith

Faculty Advisor: 
Dr. Bade Shrestha

Experimental scramjet aircraft research has been conducted for over 70 years. However, the technology is still limited due to a lack of accessible studies. To provide access to university-level research, a supersonic combustion test section was designed. By determining key parameters throughout the system using computational supersonic flow relations, an air supply, safety features, and test controls were developed. These components enable controlled flow to the testing chamber. Continued lab studies using this equipment will offer insights into the practical applications of scramjet technology

Synthesis and Characterization of Polyoxometalate-doped Carbon Material for Proton Exchange Membrane (PEM) Fuel Cells

11 to 11:25 a.m.

Team Members:
Luis Jacobo
Corey Allmon
Camila Castillo Cedeno

Faculty Advisor:
Dr. Muralidhar Ghantasala

A graphdiyne-based catalyst was synthesized and characterized to replace platinum, reducing production costs and improving accessibility. The catalyst was developed using polyoxometalatedoped carbon materials and evaluated for its structural, chemical, and electrochemical properties. Testing demonstrated promising electrochemical characteristics ensuring performance efficiency in energy applications. These catalysts offer a cost-effective alternative for PEM fuel cell technologies.

Die Casting in a Box 4.0

11:30 to 11:55 p.m.

Team Members:
Nathan Chatman
Demitrios Cortez
Noah Taulbee

Faculty Advisors:
Dr. Sam Ramrattan
Dr. Muralidhar Ghantasala

The Die Casting in a Box 4.0 machine produces WMU stamped coins made from melted babbitt alloy. The mobile and compact machine has been a long-standing project that is designed to educate students on the die casting process in real-world applications.  A refined and compacted temperature sensing system has been developed to enhance the rate of heat transfer. The programming has also been enhanced to reliably produce 10 babbitt alloy coins along with a sweeping device to remove obstructions from the die casting process.

Variable Volume Mini-Fridge

1 to 1:25 p.m.

Team Members:  
Ryder Dietz
Quinn Kelley
Jacob Roberts

Faculty Advisor:  
Dr. Kristina Lemmer

In dorm rooms and small apartments, floor space is a limited resource. The residents in these spaces often opt for a mini fridge to save on floor space. However, the freezer and fridge volumes are set, and residents may find a need for either to be larger. The variable volume mini-fridge offers users the ability to change the location of the shelf that separates the freezer and fridge volumes. Moving the shelf down increases the freezer volume, allowing for more frozen items to be stored. The moving shelf allows the users to have mini fridges with freezer or fridge spaces that fit their needs and can adjust to meet those needs as they vary with time.

Real-time Mass Flow Rate Measurements within a Single Passive Electrospray Emitter

1:30 to 1:55 p.m.

Team Members:
Carter Simmons 
Owen Hoover 
Josh Fair 
Trent Grenell 
Ryan Mullens

Sponsor:
WMU Aerospace Laboratory for Plasma Experiments (ALPE)

Faculty Advisors:
Dr. Kristina Lemmer 
Dr. Nicholas Taylor 

Current mass flow rate sensors for electrospray emitters require the measurement of the initial and final masses of an electrospray’s ionic liquid reservoir. To improve upon this system and obtain real-time measurements, a mass flow rate sensor was created to turn the ionic liquid reservoir into a capacitor by placing two electrodes between the reservoirs and measuring the change in capacitance as the propellant level is reduced. To achieve this our team designed, fabricated, and tested extraction electrodes, an excitation circuit, a detection circuit, and a temperature sensor which were fitted to the electrospray emitter. Throughout this project we implemented mechanical design, circuit analysis using LTspice, custom LabVIEW VI’s for temperature control, and sensor testing using resources provided by the Aerospace Laboratory for Plasma Experiments.

Western Aerospace Thin-Sat (WATS) Project

2 to 2:25 p.m.

Team Members: 
Tom Scott
Grace Kraft
Mason Cunningham
Cameron Larson

Sponsors: 
Dillon Embry, Near Space Education Launch Inc.
Matt Orvis, Near Space Education Launch Inc.
John Pugsley, Near Space Education Launch Inc.

Faculty Advisor: 
Dr. Kristina Lemmer

Langmuir probes are an instrument commonly used to measure the characteristics of plasma. In electric space propulsion Langmuir probes are critical in evaluating the performance of innovative technologies. A satellite BUS provided by Near Space Education will be used to carry a payload consisting of such an instrument in orbit. The payload was carefully designed and tested to ensure it can survive and operate in the harsh space environment. A successful mission will provide valuable insight and validation to the research being conducted by WALI and ALPE on campus.

Fundamental Aerodynamics of a Bat Wing

2:30 to 2:55 p.m.

Team Members:
Samantha Filipich
Jackson Kendall
Andrew Lustila

Faculty Advisor:
Dr. Tianshu Liu

Bat flight is a complex, unsteady aerodynamic feat due to its dynamically changing wingspan and pitch angle. It relies on leading edge vortices, whose skin friction has not been directly examined on a bat wing model. To gain insight into this phenomenon, three-dimensional bat wings were designed and printed at five different phases of the flapping cycle. The models were tested in a wind tunnel to examine the leading-edge vortex generation by using global luminescence oil film, optical velocimetry methods, and aerodynamic forces. The combined results of the models led to new discoveries in the understanding of biological flight.

Automation of a Medical Device Sterilization Unit

3 to 3:25 p.m.

Team Members:
Michael Drobny
Jon Hegemier 
Madeline Rousseau

Sponsor: 
Sameer Singh, Stryker Corporation

Faculty Advisor:
Dr. Richard Meyer

Stryker employs sterilization units for accelerated lifecycle testing that require manual intervention to start the cycles and clear error codes, costing about $14,000 per unit annually in technician time. To address this, an external automation system was designed to interact with the display. Automated button pushing was achieved with actuators, positioned at critical button locations, controlled by a microprocessor using machine learning for display recognition. The system reduces technician interaction time and increases intervals between interventions, ultimately reducing operating costs and shortening lifecycle testing time.

Study on the Emission Quality of Different Fuels on Swirl Burner

3:30 to 3:55 p.m.

Team Members:
Johan Gonzalez
Joan Jerez
Miguel Hernandez

Faculty Advisor:
Dr. Shrabanti Roy

This research investigates the efficiency and environmental impact of different fuels under swirl burner condition, which are commonly used in industrial combustion processes. Using ANSYS Fluent software, the study focuses on how flow conditions and boundary settings affect combustion efficiency and pollutant emissions. The main goal is to understand how to reduce harmful emissions, such as nitrogen oxides (NOx) and carbon monoxide (CO). Different fuels, including traditional and alternative options, are compared to identifying the one with the least environmental impact. The research also examines the balance between achieving high efficiency and reducing emissions. This work aims to contribute to the development of cleaner and more sustainable combustion technologies for industrial use.

Session Chairs: Drs. Pnina Ari-Gur and Zach Asher

Presentations will take place at Floyd Hall in room D-210.

Ball Valve Cycle Test Stand

8:30 to 8:55 a.m.

Team Members: 
Clyde DeLaet
Derek Rapa

Sponsor:
Parker Hannifin

Faculty Advisor: 
Dr. Jinseok Kim

Ball valves play a critical role in fluid systems, and understanding their performance over time is essential. Achieving this requires extensive cycle testing to simulate lifetime usage. The previous cycle test stand at Parker Hannifin faced reliability issues due to side loads exerted on the valve during actuation, which led to premature and inconsistent failures. To address this, a new ball valve cycle test stand was developed, capable of actuating two pressurized ball valves at variable cycle speeds. The redesigned system offers reliable operation with minimal maintenance requirements and features a user-friendly interface for straightforward operation and efficient data recording.

Boeing 747 Fixed Drive Link Redesign 

9 to 9:25 a.m.

Team Members:
Blaise Keller
Blake Tartoni 
Eric White

Sponsor:
Steve Brewer, Kalitta Air

Faculty Advisors:
Dr. Jinseok Kim 
Dr. Kapseong Ro

Safety is the top priority for engineers when completing a project. In the case of the Boeing 747, safety was being compromised through the failure of the flap actuation system, specifically, cracking in the fixed drive link. This task was taken on to ensure safety without the necessity of constant overhaul and replacement of the part. Finite Element Analysis was used to analyze the stress field on the fixed drive link. Computational Fluid Dynamics was used to interpret the aerodynamic loads on the part. A successful redesign resulted in the ability for the part to withstand aerodynamic loads experienced during takeoff and landing.

Safety System Design for CAViDS High-Speed Test Stand

9:30 to 9:55 a.m.

Team Members:
Sawyer Jones
Juan Sanchez 
Ally Schaupp

Sponsor:
WMU Center for Advanced Vehicle Design and Simulation (CAViDS)

Faculty Advisor:
Dr. Claudia Fajardo

Testing gears at high rotational speeds of up to 20000 revolutions per minute poses great danger in the case of failure. An existing safety system design for the test stand was created and altered using SolidWorks, a 3D modeling software. The new system provided adequate protection from broken high-speed shafts and reduced the time needed to run gear tests. The altered system eliminated the risk of lifting a heavy metal plate to perform each test through the sliding design. The system was also tested with an impact analysis using ABAQUS FEA. A portable heat protection system was also created for the heaters of the lubrication system used in the test stand. The completed safety system will aid in the efficiency and safety of future high speed gear testing.

Automated RoboDrill Flowmeter Test Stand

10 to 10:25 a.m.

Team Members:
Kyle Wagner
Jack Darling
Jordan Stasa

Sponsor: 
FEMA Corporation

Faculty Advisor:
Dr. Claudia Fajardo

The testing of a manufactured part is paramount to quality, reliability, and product functionality. An automated hydraulic test stand used to measure hydraulic flow in machined valve bodies was designed and prototyped to replace an existing production fixture. The safety, quality, measurement system capability, and compatibility with the existing production line were all considered in the design. The performance of the test stand was analytically predicted using fundamental principles of heat transfer, and fluid mechanics, while complying with industry standards. The resulting prototype was evaluated in an ISO 17025 and ISO 9001 certified laboratory. The use of the automated hydraulic test stand is anticipated to increase production capacity, improve gauge repeatability and reliability, and allow for the reallocation of operator labor.

Portable Hydroelectric Generator

10:30 to 10:55 a.m.

Team Members:
Marcus Kostrzewa
Samuel Reynolds
Christian Roth

Faculty Advisor:
Dr. Matt Cavalli

Small scale electric generation has grown vastly in recent years but is largely restricted to solar panel and wind turbine power production. Research was conducted on the viability of small scale, non-fixed infrastructure, hydroelectric generators as an alternative. A three-dimensional model of an axial flow, hydroelectric generator with vertical and angular adjustments utilizing a permanent magnet motor for power generation with integrated circuitry to regulate output was created using SolidWorks and LTspice. A prototype was fabricated and tested to validate performance. The finished prototype supports further development of non-fixed infrastructure hydroelectric generators as an alternative for small scale power production.

Design and Optimization of a Two-Stage Rocket for Low Earth Orbit Reconnaissance Payload Delivery 

11 to 11:25 a.m.

Team Members: 
Andrew Farnum 
Naveen Ranasinghe

Faculty Advisor: 
Dr. William Liou

As the demand for space exploration continued to rise, the need for efficient and cost-effective launch vehicles became increasingly crucial. This project aimed to enhance the rocket’s efficiency by improving propulsive performance and reducing the cost of Low Earth Orbit (LEO) payload delivery. Computational Fluid Dynamics (CFD) simulations were conducted to analyze the rocket’s performance and identify potential areas for improvement. A scaled model of the rocket was produced to demonstrate the optimizations and validate the simulation results. Ultimately, this project contributed to the development of more efficient and cost-effective rockets for future defense use and commercial applications.

Formula SAE EV: Topology Optimization of Motor and Differential Mounts 

11:30 to 11:55 a.m.

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 utilizes an iterative design process to identify designs from hardpoint, loading, and manufacturing constraints. Finite Element Analysis (FEA) validated that the final geometry will withstand 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.

Leak Test Stand Process Change 

1 to 1:25 p.m.

Team Members:
Samuel Hermon
Eduardo Patino

Sponsor:
Evan Milburn, B.S.E.’19, Denso Manufacturing Michigan

Faculty Advisor:
Dr. Javier Montefort

The Engine Cooling Module in a vehicle is responsible for regulating the temperature of the engine. If the radiators on this assembly are damaged, it can lead to coolant leaks and potentially cause the engine to overheat. To combat this, a Leak Test Stand was designed, built, and installed at the end of the assembly process to gage both the High and Low Temperature Radiator functionality. Based off this testing, the leak tester makes an accurate assessment if the assembly can then be sent to the customer or if the radiators need to be scrapped.

Flight Dynamics of Flying Wing UAVs with Morphing Winglets 

1:30 to 1:55 p.m.

Team Members:
Abdul Khan Lopez 
Carlos Zamorano Guerrero 
Benjamin Olivo Guzman

Faculty Advisor:
Dr. Kapseong Ro

This project explored the aerodynamic advantages of incorporating morphing winglets into flying wing UAV designs. Flying wings, known for their high aerodynamic efficiency, face challenges in stability and control due to the absence of traditional tails. By dynamically adjusting winglet shapes during flight, morphing winglets optimize aerodynamic performance, reduce drag, and improve yaw stability. This study included computational modeling and aerodynamic simulations. The results aimed to demonstrate improved lift-to-drag ratios, reduced wingtip vortices, and enhanced flight stability, paving the way for more efficient and adaptable UAV designs.

Archimedean Turbine Blade: Optimizing Low-Speed Wind Energy 

2 to 2:25 p.m.

Team Members: 
Emily McWethy 
Willem Miret

Sponsors:
Brian Montgomery, WMU Bronco Construction Research Center

Faculty Advisors:
Brian Montgomery
Dr. David Moussa Salazar

The wind industry is continuously trying to enhance energy generation efficiency and in addition reduce environmental impact. Archimedean Turbine blade designs address these challenges by channeling air down a shaft, allowing greater yield in slower wind conditions, and by mitigating wing tip vortex formations is able to reduce noise by a significant figure. Advanced tools including a wind tunnel, anechoic chamber, and computational fluid dynamics software were employed to derive performance metrics of the blade. Due to its sleek, compact and noiseless design, this blade is being optimized for the private and residential sector, where unobtrusive methods are preferred.

Automated Shuttle Service for Students with Disabilities at Western Michigan University 

2:30 to 2:55 p.m.

Team Members: 
Jose Marin 
Logan Miller 
Malachi Miller 
Francisco Pahuamba

Faculty Advisors: 
Dr. Zachary Asher 
Dr. Nicholas Brown

Disabled students often face significant challenges in navigating campus efficiently and independently. To address this, an automated vehicle was developed using advanced tools such as GPS navigation systems, LiDAR sensors, and machine learning algorithms. A carefully designed floor plan, complete with a wheelchair lift and secure seat installation, maximizes safety and accessibility for all users. Additionally, a camera-based motion detection system enhances safety by identifying and responding to obstacles in real time. This innovative solution goes beyond transportation—it enhances campus inclusivity by empowering students with mobility limitations, providing them with greater independence and equal access to education and activities across campus.

Garbage Bin Critter Intrusion Prevention (closed to the public)

3 to 3:25 p.m.

Team Members:
Jacob Hough
John Norman
Hunter Gracey
William Pranger

Sponsor:
Lisa Rosinski, Detroit Manufacturing Systems

Faculty Advisor:
Dr. Daniel Kujawski

The purpose of this project was to design and test a garbage bin lock that can be attached to any residential trash bin in order to prevent the entry of any small animals. The first step to this was to ensure that the lock would be easy to assemble to any bin and not come loose. Stress tests were completed to show that the critter intrusion prevention device could withstand the required stress levels.

Full-Flow Stage Rocket Engine 

3:30 to 3:55 p.m.

Team Members: 
Ahmad Al Saadi 
Tamir Almasarweh 
Wesley Banks

Faculty Advisor:
Dr. Christopher Cho 

Rocket engines are a feat of engineering that drive a sense of triumph and propels innovation. From design to a successful mission, there are many aspects of an engine that require both efficiency and precision. Full flow stage engines are a specific type of engine that maximizes power while being a viable solution for sustainable space travel. This team created an optimized prototype of a full flow stage engine by increasing the efficiency of nozzle cooling and testing variable turbo pump designs. This was achieved by experimenting with different regenerative nozzle patterns and simulating combustion using CFD.

Presentations will take place at Floyd Hall room D-109.

AI Automation in Aviation Maintenance Inspection Applications 

9 to 9:25 a.m.

Team Members: 
Ryan O’Meara 
Nathan Puma 
Andrew Swihart 
Nicholas Zomer

Sponsors: 
Alro Metals Outlet 
GoBilda Robotics

Faculty Advisor: 
Dr. William Liou

Time is a crucial limitation for airlines around the world, especially with the growing demands for commercial air travel. Utilizing an autonomous imaging robot and AI image/video processing tools, the use of automation to expedite maintenance inspections was explored. An evaluation of data provided from testing was conducted and future applications for AI in maintenance inspections were explored. Evaluations of safety factors and the limitations of AI in this application were also performed. This research and development project can be used to look at one potential solution to the ever-present problem of turnaround time, as well as to see the limitations and applications of AI in the field.

Solar Module Material and Support Testing

9:30 to 9:55 a.m.

Team Members:
Darbi Dorr
Riley Fuller 
Jadon Kennell

Sponsor:
WMU Sunseeker Solar Car Project

Faculty Advisor:
Dr. Muralidhar Ghantasala

Industry Mentor:
Dr. Mitchel Keil

Sunseeker Solar Car Project manufactures and uses solar modules with a specific material composition to power their car. A material analysis was done, and new materials were chosen based on specific properties (ex. transmissibility). Power losses were then measured using an IV tracer at a measured irradiance that shows the difference between the power output through the specific layering. The results were then compared to the current modules showing how the materials change the output power. A strain analysis was done, a new material layer was added, a new strain relief bracket was designed and analyzed using SolidWorks and Ansys. The integrity of the solar module connection points was evaluated.

Universal Attachable Backpack Stand

10 to 10:25 a.m.

Team Members:
Caleb Mast
Brandon Rus
Garrett Scherer

Faculty Advisor:
Dr. Jinseok Kim

In wet, muddy, or snowy conditions activities such as hiking, camping, or hunting, setting a backpack or knapsack on the ground is inconvenient. To avoid this inconvenience, a device was designed to elevate the backpack or knapsack. Important factors when creating such a product include being light enough not to add strain to the user, while also noting that in some cases the weight inside the backpack or knapsack can be fairly large. It is also important that the product be reusable, therefore a design using screws or bolts does not suffice as they would destroy the user’s backpack or knapsack. Using a mixture of plastic and aluminum, as well as magnets, such a design has been created.

Replicating Engine Frequency for Pre-Cleaner Testing

10:30 to 10:55 a.m.

Team Members:
Ryan Clary
Samanatha Estes
Larissa Fettig

Sponsors:
Erich Fedak, B.S.E.’03, MANN+HUMMEL
Josh Wylie, B.S.’21, MANN+HUMMEL

Faculty Advisor:
Dr. Jinseok Kim

Automotive filtration narrows down to separating the useful from the harmful. Pre-cleaners are used to improve this process. A lab standard for emulating engine vibration has not been replicable until now. This method has been designed, simulated, and tested to improve the accuracy of pre-cleaner testing. Using simulations, frequency drives, and a tachometer the best frequency was found to emulate machine conditions for testing. This set up is used for all pre-cleaners where vibration is used in dust flow testing. The device will be the standard for these tests going forward.

Deployable Assembly Structure and Harnessing for a Langmuir Probe (DASH-LP) 

11 to 11:25 a.m.

Team Members: 
Sean Cowell 
Luke Halladay 
Katherine Reischman

Faculty Advisor: 
Dr. Kristina Lemmer

Deployable structures are often used in satellites. The CubeSat being designed by Western Aerospace Launch Initiative will have a fiberglass-type boom paired with a sensor, which requires auxiliary support structures. Designs for the cabling system for the sensor, as well as mounting structures for the probe and stowed cable were developed and prototypes prepared. These models were analyzed using Finite Element Analysis to evaluate stress and displacement under launch loads. Testing on prototypes was conducted to evaluate solution performance and iterate the designs. Supplementary documentation will allow the WALI team to iterate and adjust these as necessary.

LX 450 and 80 Series Landcruiser Rear Off-Road Bumper

11:30 to 11:55 a.m.

Team Members:
Colin Gregory 
Matthew Piscoran 
Luke Weisser

Sponsor:
Brian Meyers, Victory 4x4

Faculty Advisor:
Dr. Matt Cavalli

Overlanding is a form of off-roading that involves traveling large distances in remote areas, typically with very rugged and demanding terrain where collisions are common. A durable, corrosion, and impact resistant steel bumper was created by taking a 3D scan of the rear frame of the vehicle to create a precise digital model. The computer-aided design software, SOLIDWORKS, was then used to model the new off-road capable bumper. This new rear bumper features crucial protection of the rear of the vehicle as well as better ground clearance and robust recovery points.

Wind Turbine Noise Reduction

1 to 1:25 p.m.

Team Members:
Steven Davenport
Macayla Wright
Angelica Zoch

Faculty Advisors:
Rishav Mishra
Dr. Bade Shrestha

Wind turbines generate noise from the air flow over the turbine blades. A baseline NACA 0012 airfoil was created in the computer-aided engineering software, SolidWorks and 3D printed. Additional airfoils were then created with modifications to lessen the turbulence and noise generated. These airfoils were tested in a wind tunnel inside of an anechoic chamber. Improvements were also made to the wind tunnel by adding acoustic foam and a new support system for the airfoils. Simulations of the airfoils were conducted with a fluid simulation software, Ansys Fluent. Results from the wind tunnel tests and Ansys simulations were used to determine the effective designs for reducing noise. Post processing of the experimental data was done with code provided by previous senior design projects. Recommendations were provided for future research in this area.

Multi Tilt Tablet Arm Redesign

1:30 to 1:55 p.m. (closed to public)

Team Members:  
Hassan Alshakal
Noe Badillo

Sponsor:  
Chuck Beasley, Haworth Inc.

Faculty Advisor:  
Dr. Daniel Kujawski

Ergonomic chairs are in high demand in the furniture industry, and currently, there are no competitors who offer a tablet armchair, that allows both the tablet to extend and rotate whenever needed. The ergonomics benefits that stem from such a product are too beneficial to be ignored. With the use of PTC Creo, and Computer Aided Design program, and repeated prototyping and testing such a product came to fruition. The prototype was insured to meet the BIFMA standards required by furniture manufacturers through constant testing of both static and dynamic loads.

Design of an Experimentally Correlated Thermal-Flow Simulation of an FSAE Radiator 

2 to 2:25 p.m.

Team Members:
Andre Fernandez
Brennan Holton
Vinicius Fernandes Sena

Faculty Advisor:
Dr. Kristina Lemmer

The primary goal of this project was to contribute to the WMU FSAE team by designing a thermal-flow simulation capable of qualifying suitable radiators. This is important due to the high difficulty and labor of “in-house” radiator production. This project was not intended to select a radiator for the team, but instead to develop a systematic process of experimental data that can be used to enhance accuracy of Computational Fluid Dynamics simulation, thus enabling proper radiator duct design enhancing overall vehicle performance.

Autonomous Vehicle Sensor Performance Research and Aerodynamic Shroud Development for Sensors 

2:30 to 2:55 p.m.

Team Members: 
Keefer Livingston 
Jordan Shimunek 
Andrew Stock

Sponsor: 
Matt Pienta, Ghostworks

Faculty Advisors: 
Dr. Zachary Asher 
Dr. Nicholas Brown 
Dr. Johan Fanas

Autonomous vehicle technology is an industry that is in a constant state of growth, becoming a key interest for large vehicle manufacturers across the globe. With more Universities and third-party development companies wishing to enter the industry, there is a need for a tested and known baseline with which research can be started affordably. For this reason, the current autonomous sensor layout being used as a part of Energy Efficient Autonomy Research lab was modified to form a safe and cost-effective solution with analysis performed in multiple everyday occurrences. The majority of the sensors used in this design are placed on the roof with a rack assembly, resulting in a need to help reduce the drag caused by the sensors to extend the range of the autonomous vehicle. An aerodynamic shroud was designed using SolidWorks and subsequently tested using Ansys Fluid, creating a diversion of flow around the roof rack assembly.

Presentations will take place at Floyd Hall room D-109.

Quadcopter Trajectory Optimization and Control

Design and Development of Unmanned Aerial Vehicle for Cloud Seeding 

Scramjet Combustion Lab Test Section Manufacturing Project

Wind Turbine Aeroacoustic Noise Reduction 

Presentations will take place at Floyd Hall room D-210.

Design of Telemetry and Remote-Control System for Electric Propulsion Testing

Variable Wind Turbine Pitch Mechanism