eProjects (EGR 402) 

Professional Design Project II is comprised of students from the BSE Engineering program (with concentrations in Automotive Systems, Electrical Systems, Mechanical Systems, and Robotics Systems) and the BS Manufacturing Engineering program.

Spring 2024 projects

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Team 01: Universal Helicopter Transmission Test Stand
Students: Justin Alam, Richard Green, Connor OHara, Jay Teer, Collin Zinn
Sponsor: Able Aerospace Services

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This project aims to design a modular test stand to test multiple transmission types, addressing capacity limitations. Able Aerospace, a Textron subsidiary, specializes in aerospace manufacturing, including rebuilding helicopter transmissions.

 

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Team 02: Workstation for Oversized Window Wall Assembly
Students: Andrew Sarrasin, Samuel Striffler, Brennan Wagner
Sponsor: Andersen Windows & Doors

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This team partners with Andersen to design an assembly table for Heritage catalog window-wall units, focusing on cost and efficiency. The deliverable is a CAD model featuring an actuating tilt-table.

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Team 03: Photovoltaic Module Mechanical Load Test Device
Students: Fatema Alshehhi, Enoch Choi, Tristan Dunton, Adam Swanson
Sponsor: Array Technologies

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Array Technologies, a veteran in solar PV tracking, collaborates with ASU to bolster design integrity against wind and snow loads. This team aims to enhance testing efficiency with a suction cup device, ensuring precise data collection to meet industry standards.

 

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Team 04: Collaborative Robotics Safety Verification
Students: Sam Kohler, Garrett Kolowitz, Jake Okun, Jedriq Ventura
Sponsor: Boeing

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This project partners with Boeing to improve risk assessment methods for collaborative robots, proposing standardized validation approaches to enhance manufacturing safety and automation integration.

 

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Team 05: Storage Solutions for Industrial 3D Printer Filament
Students: Tanner Atkinson, Zachary Chesler, Hasan Kaysan
Sponsor: Collins Aerospace

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This team partners with Collin’s Aerospace, a leading aerospace component supplier, to enhance filament storage and monitoring in their Phoenix makerspace. Their solution involves a shelf with an integrated scale and LED screen for easy filament level monitoring.

 

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Team 08: Siemens Automation Trainer in a Box
Students: Carlos Chacon Cuesta, Trent Packer, Mark Karlo Salazar, Knight Wolff
Sponsor: Heitek Automation

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Siemens USA, Heitek Automation and Arizona State University are developing a “Siemens Automation Trainer in a Box” to meet the increasing demand for industrial automation engineers in the US.

 

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Team 09: Industry 4.0 Automation Training Workstation
Students: Michael Angelico, Abigail Gordon, Daniel Koltsov, Richard Kovalcik
Sponsor: Heitek Automation

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This team and Heitek collaborate to update ASU’s manufacturing lab with an Industry 4.0 automation training workstation, replacing old pick and place machines. The system offers realistic digital training, preparing students and employees for automation’s future.

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Team 10: Hydrogen Powered Delivery Drone
Students: Madison Hedges, Kayden Lewis, Morgan Strube, Tyler Winder
Sponsor: Honeywell Aerospace

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In partnership with Honeywell, students are pioneering a project to integrate hydrogen fuel cells into ground drones for food delivery, extending range and reducing emissions. This aligns with global efforts for greener transportation in last-mile delivery services.

 

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Team 11: Small Hydrogen Vehicle Refueler
Students: Jadrian Padilla, Jordan Phillips, Jose Juan Roman
Sponsor: Honeywell Aerospace

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Hydrogen’s potential in transportation is hindered by infrastructure gaps. Collaborating with Honeywell Aerospace, our team aims to develop compact hydrogen refuelers for vehicles or fuel cells, using electrolysis-based generation and overnight refueling for cost efficiency.

 

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Team 12: Design and optimize the AM HX Inlet Outlet Plenum
Students: Dawson Francis, Desiree Lopez, Juan Uribe
Sponsor: Honeywell Aerospace

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Honeywell Aerospace explores additive manufacturing’s potential in heat exchanger designs, aiming for durability and efficiency. They collaborate with Arizona State University students to optimize AM inlet and outlet plenum design, reducing stress and pressure drop.

 

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Team 13: FPGA-based Avionics System for UAVs
Students: Avery Russell, Tilak Raj Thanga Raj, Finnton Wentworth
Sponsor: Honeywell Aerospace

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This team collaborates with Honeywell to design an FPGA-based drone. They chose hardware, developed a custom PCB enabling communication among the FPGA, IMU, servos and motors, GPS and airspeed sensor and created software to control all servos and motors.

 

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Team 14: Improving Operational Safety with Netilion IIOT Ecosystem
Students: Nathan Hoge, Shalane Milford, Ian Wiltz
Sponsor: Endress + Hauser

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In partnership with Endress and Hauser, Instrumentation and Controls LLC seeks to enable real-time data access for customers. Utilizing wirelessHART signals and IIOT, our solution involves transmitting sensor data to a cloud server hosted on Netilion with a customized interface.

 

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Team 16: Robotic Vision Inspection Training Station Retrofit
Students: Yiyang Lin, Alexander Merret, Cayman Preston, Leah Stewart
Sponsor: Kredit Automation & Controls

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This machine, developed with Kredit Automation and Controls, acts as a training station for automated hardware. Users are instructed in operating components like the FANUC SCARA Arm and Cognex Vision System. Its main function involves placing a Rubik’s cube on the dial, rotating it, conducting a pass-fail test with the Cognex Camera and returning the cube to the operator.

 

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Team 17: Gear Grinding Table Handling and Storage
Students: Kaleb Alexander, Jesse Cabrera, Luis Estrada
Sponsor: L&H Industrial

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This team partnered with L and H Industries, a prominent custom manufacturing firm in Tempe, Arizona. Tasked with addressing storage challenges during facility renovations, the team’s focus shifted from moving and rotating oversized gear tables to designing a space-efficient storage solution capable of supporting the weight of two tables when stored vertically.

 

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Team 19: Thermal Response of Non-Volatile Memories
Students: Michael Kelpien, Walid Khan, Hector Peralta
Sponsor: L3 Harris

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L3 Harris, a leading manufacturer of flight data recorders, focuses on ensuring the reliability of Non-Volatile Memories, or NVMs, within their black boxes, crucial for data retention during extreme conditions. The team proposes a rigorous testing process involving thermotron exposure to assess NVM quality, offering valuable insights for L3 Harris and its customers, ultimately enhancing data reliability post-event.

 

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Team 20: Yeast packaging yield
Students: Eamon Geraghty, Jacob Mitchell, Jacob Tangeman
Sponsor: Lallemand Inc.

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Lallemand Baking, manufactures yeast in various forms at its Memphis plant, facing challenges with yeast loss during packaging, which increases production costs. This project aims to identify, quantify and monitor these losses through a real-time Grafana dashboard, seeking to optimize packaging efficiency and reduce costs.

 

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Team 21: Cooling capacity and requirements of yeast fermentation
Students: Mark Alvarez, Trevor Kowal, Anyssa Lomeli
Sponsor: Lallemand Inc.

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Lallemand Baking, a global leader in baker’s yeast production, focuses on optimizing efficiency while maintaining precise temperature control during fermentation. This team’s task is to enhance the existing system through data analysis and a dashboard to ensure optimal cooling capacity and process efficiency without altering fermentation processes.

 

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Team 23: Manufacturing Integration Problem
Students: Taylor Gowdy, Marcus Lemke, Daymon Wilkins
Sponsor: Los Alamos National Laboratory

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This team, sponsored by Los Alamos National Laboratory, or LANL, aims to integrate LIBS technology into LANL’s manufacturing line for rapid sample analysis. They developed an automated test fixture with a LIBS tool to streamline sample analysis and improve manufacturing efficiency, presenting their findings during a March site visit at LANL.

 

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Team 26: Robotic arm actuated Glovebox operations
Students: Harris Brody, Aaron Karsten, Jacob Pisors
Sponsor: Los Alamos National Laboratory

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In collaboration with Los Alamos National Laboratory, this project addresses strain on glovebox operators during object disposal, particularly concerning damage to barrel liners. It involves integrating a collaborative robot to safely dispose of objects, enhancing safety and efficiency while minimizing liner damage and operator strain.

 

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Team 27: Robotically Assisted Exoskeleton for Glovebox operators
Students: Stefano Greco, Claire Rogers, Crystal Torres
Sponsor: Los Alamos National Laboratory

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Operators in gloveboxes endure significant muscle fatigue due to task complexity and the unnatural glove working position. This project aims to develop a powered wearable exoskeleton to alleviate this fatigue, prioritizing portability, ease of use and smooth operation. The segmented harness exoskeleton is designed to address extended physical strain while remaining portable and non-inhibiting for operators.

 

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Team 29: Quick Change Vacuum Chuck
Students: Carlos Duarte, George Kobel Buelna, Nayeli Rodriguez
Sponsor: Los Alamos National Laboratory

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Los Alamos National Laboratory uses vacuum pot chucks to machine plutonium hemishells, requiring quick chuck changes with limited hand mobility inside glove boxes. To address this, the team devised a tool-less interlocking method using quarter turns for efficient alignment, replacing the current bolt-based approach.

 

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Team 30: Automate Manual Solder Bridging Checks
Students: Ibrahim Alhassan, Eduardo Lopez, Jose Nava-Mesina, Salsabil Abdelhamid Soliman
Sponsor: Lucid Motors

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Focused on Lucid Motors’ Multipurpose box, or MPB, this project involves collaboration with Sarvesh Paranjape, a Manufacturing Engineer. To address potential circuitry issues caused by over 100 soldered pins prone to damage and solder bridging during assembly, a fixture has been developed to automate electrical tests on the MPB. This ensures the integrity of the MOSFET chips and identifies any soldering bridges or electrical faults.

 

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Team 31: Automation Training Station Design and Build
Students: Ragde Chaira-Gouzounis, Morgan Nunez, Charles Schartman
Sponsor: Maskine

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This team partners with Maskine, a Phoenix-based industrial automation firm, to develop a training station integrating a PID controller and other components. This station simulates automation processes using a gumball machine to provide comprehensive training for engineers.

 

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Team 32: Solder Paste Printing Optimization
Students: Andres Duran, James Kaminsky, Christian Petey
Sponsor: Mercury Systems

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This team partners with Mercury Systems to optimize solder paste application on their surface mount technology lines. They analyze data from screen print machines to adjust variables like squeegee speed and pressure, ensuring desired solder height and area on motherboards. Tests at Mercury Systems’ facility inform adjustments for each board, analyzed with Minitab for optimal results.

 

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Team 34: Launch Vehicle Spin Balance Mechanism
Students: Ian Davis, Michael Fuhrman, Jacob Naylor-Ott, Dylan Turner
Sponsor: Northrup Grumman

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Accurate mass property measurement is vital for aerospace vehicle trajectories and maneuvers. To address the costliness of spin balancers, Northrop Grumman proposes a scalable device for measuring mass properties. This solution integrates static and dynamic measurement systems with advanced circuitry to measure mass, center of gravity, moments of inertia and products of inertia for various-sized objects, ensuring scalability to larger launch vehicle assemblies.

 

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Team 35: Wearable Electronics for Monitoring Astronaut Health
Students: Zachary Felty, Delanie Krug, Hunter Mullins, Glen Stevens
Sponsor: Paragon Space Development Corporation

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Paragon develops life support systems to regulate oxygen and humidity for human survival. Their project focuses on creating a wearable monitoring system for early detection of fatigue or hypoxia in extreme environments. The device, with a pulse oximeter and electrodermal sensing, ensures safety for individuals like divers, astronauts and first responders.

 

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Team 36: Thermal Scanning System for Bottle Coolers
Students: Miguel Chacon Cuesta, Samuel Masamitsu, Lina Mayyas, Chase McCleary
Sponsor: PepsiCo

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In partnership with PepsiCo, this project integrates a thermal scanning system into Gatorade production lines for quality assurance. It automates temperature monitoring and adjustment, reducing defects and production downtime. Despite financing delays, this project pivots to connecting bottle labelers to streamline flavor and date updates, enhancing labeling efficiency.

 

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Team 37: Tumble Testing for Smartphone Security Cases
Students: Ian Bassett, Gavin Benvenuto, Abdulrizak Husein, Glen Mathew
Sponsor: Privoro

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Privoro, specializing in smart cases for smartphones to prevent unauthorized camera and microphone access, partners with this project. The task involves creating a tumble tester to evaluate their cases. The solution opts for a modified traditional tumble tester design to streamline construction and reduce costs, featuring a single side protrusion for phone insertion instead of the conventional dual protrusion setup.

 

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Team 38: Automated Material Handling Hoist
Students: Deepit Arora, Zhengbin Chen, Trevor Robertson, Mingqi Yu
Sponsor: PROD Design & Analysis

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This team partners with PROD Design & Analysis to create an Automated Material Handling Hoist for semiconductor fabrication facilities. This project addresses the need for efficient handling of silicon wafers within these facilities. Their focus lies in designing a lifting mechanism for transporting wafer containers between machines onto an elevated track.

 

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Team 39: Roll-Out Cart High-Capacity Storage Solution
Students: Samuel Coltrin and Scott Sorensen
Sponsor: Rehrig Pacific Company

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Rehrig Pacific partners with this project to tackle space inefficiencies and safety issues in their warehouses. The solution involves a vertical racking system for their new Buckeye, AZ warehouse, doubling storage capacity and ensuring safety with two levels of roll-out cart stacks. Successful implementation will set a blueprint for expanding this design across all Rehrig Pacific warehouses, improving storage capacity and safety standards.

 

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Team 40: Precision RF Connector Scanner
Students: Kevin Hays, Felicia Szleszinski, Levi Transtrum, Miles Wilson
Sponsor: Raytheon (RTX)

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Improving radio-frequency signal transmission in multi-path systems requires replacing mechanical switches with precise RF connectors, yet human intervention poses a challenge. Developing a robotic solution is daunting. This team, alongside RTX engineering fellow David Henderson, crafted a system using computer vision and robotics for precise RF connector mating.

 

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Team 41: Modular 6-DOF Fixed-Wing Aircraft Simulation
Students: Jaime Corral, Roman Mendoza, Trevor Wild
Sponsor: Sandia National Laboratories

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This team collaborates with Sandia National Laboratories to develop an integrated navigation system crucial for critical applications. Addressing limitations of standalone GPS and inertial measurement units, they integrate data through Kalman Filters for a more reliable location estimate.

 

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Team 44: Life sized Army truck replicating enemy missile sites
Students: Timothy Liu, Benjamin Martin, Danh Phan, Isaiah Reyes
Sponsor: U.S. Air Force

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U.S. Air Force Detachment nine, responsible for training aids, lacks suitable radar targets, impacting personnel readiness. This team’s solution involves crafting a life-size enemy anti-air missile system with tilt capability for realistic training scenarios, aiding in vital preparations.

 

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Team 46: Production Tool and Jig Management via RFID
Students: Tyler Benson, Kimberly Koppenstein, Aiden Lynch, Kyle Selasky
Sponsor: Wisk Aero

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This team partners with Wisk Aero on the “Production Tool and Jig Management via RFID and RTLS” project, aiming to prevent Foreign Object Debris (FOD) incidents in aircraft. They develop a system to detect tools within the workspace, logging their presence for timely removal, ensuring debris-free aircraft completion.

 

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Team 47: Diaphragm Pump Noise Optimization
Students: John Higby, Gary Kujawski, Adam Weiss, Braden Williams
Sponsor: Xylem

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Xylem tackles global water challenges, offering solutions across industries. Collaborating with Xylem, the team records data on flojet four diaphragm pumps to create a quieter pumping experience. This research aids in integrating noise considerations into product design, with the team developing a testing platform to address noise factors in the pump.

 

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Team 49: Tilt Up Window Automation Solution
Students: Michael Gross, Wyatte Ricks, Brendon Salido, Lukas Severinghaus
Sponsor: Summit Automation

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Summit Automation in Mesa, AZ, specializes in home automation, retrofitting doors and now eyeing window automation, especially tilt-up windows for indoor-outdoor integration. Collaborating with the ASU capstone team, they’ve developed a stylish, hands-free solution using linear actuators and a control system for modern automated homes.

 

Spring 2023 projects

Photo of EGR 402 Team 1: James Reiter, Logan Spearin, and Matthew Dsouza

Students: James Reiter, Logan Spearin, Matthew Dsouza
Sponsor: ASSA ABLOY

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Assa Abloy specializes in producing commercial opening and entrance automation devices for the global market. A challenge Assa Abloy is facing is the ability to innovate and stay ahead of the competition while also continuing its dedication to quality and safety. Assa Abloy tasked this team with producing a working prototype of a surface mount electric door strike that is creative, modular, complies with the standard for burglary-resistant electric locking mechanisms and falls in accordance with Assa Abloy’s quality and testing standards. As designed, the prototype design in this capstone project is comparable in functionality to that of the HES9600 electric door strike offered by the Assa Abloy group.

 

EGR 402 Team 2: Noah Blevins, Matthew Tucker, Joseph Kong, and Eric Nelson

Students: Noah Blevins, Matthew Tucker, Joseph Kong, Eric Nelson
Sponsor: AXON

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This team worked with AXON to transform public safety with technology and increasing the applications of drones. They were tasked with the design, fabrication and testing of a ceiling-mounted drone dock. The dock needs to charge the drone, transfer data and have rapid deployment capabilities. The team’s solution utilizes a ring mounted to the top of the drone which will connect with the dock. The charging and data transfer hardware will be mounted on the drone, below the ring and will be properly oriented via a passive landing assist system.

 

EGR 402 Team 3: Ali Aldaaysi, Gil Ruiz, Jacob Coker, Jakob Acres, Skylynn Young

Students: Ali Aldaaysi, Gil Ruiz, Jacob Coker, Jakob Acres, Skylynn Young
Sponsor: Becton Dickinson Peripheral Intervention

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In the current medical world, there is no method for dialysis patients to safely self-cannulate themselves, so they have to go to a clinic for their treatment. There are many who want to take their dialysis treatment home so they can cut down on expenses and feel more comfortable. Becton Dickinson Peripheral Intervention is a medical company that wants to make this a possibility. They tasked this team with creating a device that would allow a person to safely and reliably self-cannulate without the need for a trained professional.

 

EGR 402 Team 4: Connor Holley, Preston Miller, Zachary Rivera, Zhanyi Wang

Students: Connor Holley, Preston Miller, Zachary Rivera, Zhanyi Wang
Sponsor: Heitek Automation

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This team partnered with Heitek Automation, an engineering solutions company and distributor, to manufacture and distribute automation training modules for their customer PECO Pallet. The modules will be used to train technicians to quickly diagnose and remedy common faults in automation systems. The solution is a combination of 11 interconnected training modules that will function as a simulation of those utilized at PECO Pallet facilities.

 

EGR 402 Team 5: Anita Lu, Hunter Robertson, Jahmarley Anthony, Trentten Orth

Students: Anita Lu, Hunter Robertson, Jahmarley Anthony, Trentten Orth
Sponsor: Intel Corporation

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This team partnered with Intel to improve the efficiency of their Thermal Compression Bonding (TCB) force calibration process. TCB is the process of bonding silicon wafers to a substrate backing using heat and force, requiring an accurate force, proper alignment and a specific temperature. In the current process, the machine has to be taken offline for a minimum of six hours due to thermal and metrology limitations. That time frame may extended further due to technician errors and complexity. This team’s solution consists of a pedestal machined out of PEEK providing superior thermal insulation. A Mark-10 load cell has been implemented to provide improved metrology characteristics. These solutions together are expected to significantly reduce TCB force calibration times.

 

EGR 402 Team 6: Aaron Webdale, Jacob Butler, Matilda Jurado, Miguel Zepeda

Students: Aaron Webdale, Jacob Butler, Matilda Jurado, Miguel Zepeda
Sponsor: Lallemand Baking

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Lallemand is one of the top yeast-producing companies in the world and their goal is to create a better future for food, people, animals and the environment. They have facilities located worldwide and but this project focused on the Baltimore, Maryland plant. This plant periodically shuts down due to unwanted vibrations, which cuts into their total production rate. Lallemand has tasked us to locate, evaluate and mitigate that vibration within the plant. The industry partner and mentor James Laning is the lead engineer at the Baltimore plant and helped the team develop a solution to the problem. The group created base plates for the centrifuges that consist of aeroflex isolators to greatly reduce the vibration levels in the plant.

 

EGR 402 Team 7: Alexis Ramos, Max Low, Noah Asherbranner, Ramone Vick

Students: Alexis Ramos, Max Low, Noah Asherbranner, Ramone Vick
Sponsor: Lallemand Baking

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Lallemand Baking is a global microbial solutions provider for many diverse applications and is represented in 12 countries. The North American production facilities produce yeast, which is an essential component for the food supply chain and service industrial and mid-size bakers. At Lallemand’s North Dakota plant, mechanical chillers run year-round to cool the process water used in their yeast-making facilities. However, Lallemand is interested in switching their cooling method from mechanical chillers to a cooling tower, a device that leverages the naturally cold climate of North Dakota to chill the water. Lallemand tasked this team with conducting a study to determine whether or not cooling towers are an effective alternative to mechanical chillers. To conduct this study, the team produced an excel simulation that emulates the performance of a cooling tower based on the climate conditions of the North Dakota plant. The potential power savings of this switch can reduce utility costs by up to $800,000 per year. 

 

EGR 402 Team 8: Anthony Manalo, Nicholas CollinsYarnall, Nicholas Knowles, Vanderson Cunjuca

Students: Anthony Manalo, Nicholas CollinsYarnall, Nicholas Knowles, Vanderson Cunjuca
Sponsor: Maricopa County Department of Transportation

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The Maricopa Department of Transportation (MCDOT) manages transportation infrastructure and related services in the Phoenix Metropolitan area to ensure safe and efficient travel. As part of its responsibilities, MCDOT manages work zones and the related data to efficiently manage traffic. However, like most transportation agencies in the United States, MCDOT currently lacks accurate real-time work zone data from contractors to determine if work zones are active, which leads to unnecessary traffic delays and increased emissions. To tackle this challenge, this team developed two devices that attach traffic control devices (TCDs) to an electronic enclosure. While turned on, the low-power device will send real-time data via a cellular network to an easily accessible web server signaling that there are active work zone restrictions in place.

 

EGR 402 Team 9: Jacqueline Villanueva Castro, Jeffrey Zelkin, Jeiny Ayala, Paulina Garibay Jaquez

Students: Jacqueline Villanueva Castro, Jeffrey Zelkin, Jeiny Ayala, Paulina Garibay Jaquez
Sponsor: NASA Psyche Mission ASU

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Team Silver was tasked with developing a landing system for the NASA Psyche mission to help safely land on a metal-rich asteroid which is located near the asteroid belt. NASA’s interest in the project is to learn more about the core material and the planetary formation of terrestrial planets. Current landing systems for planets and asteroids differ due to atmospheric conditions, temperature and gravity, so this project took a mechanical approach to ensure the landing system can attach itself to the asteroid without the zero gravity bounce from landing. In addition, the team worked with other Psyche teams to design a top hatch that will be compatible with their design.

 

EGR 402 Team 10: Austin Corona, Corey Smith, Ethan Rodrigues, Zane Reynolds

Students: Austin Corona, Corey Smith, Ethan Rodrigues, Zane Reynolds
Sponsor: NASA Psyche Mission ASU

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This team collaborated with Cassie Bowman and the NASA Psyche Mission to assist in the exploration of the unknown and diverse terrain on the asteroid known as Psyche. The team’s main objective was to design and build a robotic explorer that can navigate and withstand the harsh conditions of space. To achieve this, they developed a device that can launch itself from the surface of Psyche and use its rotation to travel to specific locations. The explorer is equipped with a range of thrusters that allow for precise and efficient movements, while a hydraulic dampening suspension ensures its safety during the journey. This innovation promises to bring us one step closer to uncovering the mysteries of Psyche and its unique landscape.

 

EGR 402 Team 11: Christopher Friend, Hannah (Chloe) Brown, Yujia Wang

Students: Christopher Friend, Hannah (Chloe) Brown, Yujia Wang
Sponsor: NASA Psyche Mission ASU

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This NASA Psyche team developed a method to collect samples from the surface of the metallic asteroid called Psyche. Collecting samples from space is extremely difficult yet vital to the continuation of space exploration providing a better understanding of how our universe was formed. This project aimed to design and create prototypes of a sample return system that would keep the original integrity of the samples after collection and ensure that the quality of the samples is as close to the original composition as the asteroid for precise research purposes.

 

EGR 402 Team 12: Cecilia Alcantar-Chavez, Connor Morse, Maxwell Gould, Simon-Peter Wrublik

Students: Cecilia Alcantar-Chavez, Connor Morse, Maxwell Gould, Simon-Peter Wrublik
Sponsor: Raytheon Technologies 

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Raytheon Technologies (RTX) is one of the leading competitors in the Aerospace and Defense industry around the world. Their Javelin factory need improved on-site visual solutions such as signage, posters, bin labeling and WIP display boards to increase the facility’s operational productivity, parts traceability, organization and overall efficiency. This team developed two solutions: a parts bin label and a WIP tracking board. The parts bin label uses colors, part names, pictures and a QR code, among other things, to help keep track of parts in the factory and increase productivity by reducing time to find parts. The WIP tracking board displays operator swim lanes, production line dependencies and potential bottlenecks. Our final deliverable is a solutions packet with an explanation of the solutions, implementation plans and how the solutions could be transferred to other factory lines.

 

EGR 402 Team 13: Nathan Fahner, Parker Tidwell, Remington Tidwell, Zerek Leyva

Students: Nathan Fahner, Parker Tidwell, Remington Tidwell, Zerek Leyva
Sponsor: Raytheon Technologies 

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Raytheon Technologies (RTX) is one of the leading competitors in the Aerospace and Defense industry around the world. This team was tasked to resolve one of RTX’s complex engineering challenges. They worked alongside the operations engineering group at Raytheon Technologies based in Tucson, Arizona, to deliver a lower-risk solution for the handling of the SM-2 Standard Missile Guidance System. The current fashion in which RTX’s operators have been performing this operation has been deemed unsafe for both the handler and the GS itself. Therefore, this year’s senior capstone group has provided a solution to RTX’s problem in the form of an automatic tipping and tilting mechanism which safely secures the payload and prevents injuries during RTX’s SM-2 assembly process.

 

EGR 402 Team 14: Carlos Martinez, Jiaji Chen, Justin (Reed) Hancock

Students: Carlos Martinez, Jiaji Chen, Justin (Reed) Hancock
Sponsor: Swire Coca-Cola

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At Swire Coca-Cola, a Coca-Cola bottler and distributor located in Tempe, Arizona, it takes 1.75 to 2 gallons of water to produce 1 gallon of product and they would like to reduce that to a 1:1 ratio. Currently there are limited means to track the water usage within the production environment with the current sensors. To achieve the goal of lowering the water use ratio, or WUR, this team added comprehensive SCADA software, Ignition by Inductive Automation, to their production process to track and store data on water usage. This system will allow Swire Coca-Cola to track, store and display where their water is being used and what areas could be improved without having to change their current software or devices. With the added software, Swire Coca-Cola will be able to make data driven decisions to save money and reduce their environmental impact.

 

EGR 402 Team 15: Austin Suder, Jeffrey Noble, Michael McClaflin

Students: Austin Suder, Jeffrey Noble, Michael McClaflin
Sponsor: Mercury Systems

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Mercury Systems is a technology company that supplies computer hardware and software products for the aerospace and defense industries and they are interested in optimizing their SMT setup process. This optimization is to help with Mercury’s manufacturing production output and increase productivity. This team developed an depth analysis of Mercury’s setup process through data collected on a weekly basis. The analysis report will inform Mercury of which areas of the setup process need to be addressed to reduce downtime and increase productivity and revenue.

 

EGR 402 Team 16: Alexander Potts, Kenneth Hodson, Ryan Clark, Seth Altobelli

Students: Alexander Potts, Kenneth Hodson, Ryan Clark, Seth Altobelli
Sponsor: Mercury Systems

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Mercury Systems is a microelectronics packaging and integration company with a facility in Phoenix, Arizona. One of the steps in their manufacturing process is integrated circuit testing that involves testing microchip operation at extreme temperatures. This step is a bottleneck in the process due to the length of the test and the amount of human intervention required. To address this challenge, this team developed a removable three-axis cartesian system that sits above the tester, allowing the test to be automated without requiring specialized testing equipment. This solution uses computer vision to identify and scan chip serial numbers, pick and place chips, open and close the chip receptacle, and bin chips based on test results. This product is a low-cost alternative to existing products on the market, allowing Mercury Systems to increase production while keeping costs low.

 

EGR 402 Team 17: Ammon Hall, Benjamin Espinoza, Juan Ramirez, Tyler Hulson

Students: Ammon Hall, Benjamin Espinoza, Juan Ramirez, Tyler Hulson
Sponsor: Collins Aerospace

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Collins Aerospace is a major player in the global aerospace industry, known for its production of aircraft equipment, however, they have faced challenges when attempting to integrate a FANUC robot into their work environment that is damaging the units. In order to address this issue, this team joined forces with Collins Aerospace to simulate and demonstrate the feasibility of the proposed use case. As of right now, FANUC has been successful in delivering the requirements using a SCARA SR-i3A Robot and ROBOGUIDE.

 

EGR 402 Team 18: Danis Nugroho, Deshawn Tallsalt, Xianyao Liu

Students: Danis Nugroho, Deshawn Tallsalt, Xianyao Liu
Sponsor: Collins Aerospace

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This team worked alongside Collins Aerospace, a subsidiary of Raytheon Technologies Corporation, to develop an AGV, or Automated Guided Vehicle, that can transport 100 pounds of materials along a predefined route of at least 500 feet without collision. Collins Aerospace primarily competes in the aerospace and defense market and strives to design parts and components for commercial businesses. The main challenge that the industry partner seeks to overcome is the errors made by human material movers that have negative impacts on productivity and cost-effectiveness. By replacing human material movers with AGVs, the company can utilize resources more efficiently and reduce the expected cost impact of $120,000 per year. This project provides an exciting opportunity to enhance productivity, efficiency and safety in material transportation.

 

EGR 402 Team 19: Benjamin Yee, Daniel Brown, Kenneth Cunningham, William Davidian

Students: Benjamin Yee, Daniel Brown, Kenneth Cunningham, William Davidian
Sponsor: Collins Aerospace

Collins Aerospace Logo


This team partnered with Collins Aerospace to improve their preventative maintenance process for avionics test equipment. Over time, the primary test connectors wear and unexpectedly fail. When this happens, multiple hours are lost in diagnosing the issue instead of testing the products. The team has created a system that will utilize a barcode scanner to automatically record each interaction with the panel connectors. The information will be logged in a database to assist with scheduling preventative maintenance on these devices. Replacing these connectors after their rated lifespan will reduce troubleshooting efforts since a worn connection is one of the most common causes of a failed test.

 

EGR 402 Team 21: Austin Harmon, Dustin Sellers, Michael Reynolds, Sage Furman, Tanner Souza

Students: Austin Harmon, Dustin Sellers, Michael Reynolds, Sage Furman, Tanner Souza
Sponsor: RIGID Industries

RIGID Industries Logo


RIGID Industries is constantly developing the newest technology for the off-road lighting market. Their newest product requires a typical pod light packed with functionality. This light is looking to feature a custom charging mount that allows the light to be quickly disconnected without tools giving the user a portable utility and safety light that is always charged on battery when needed. Rigid Industries’ customers are looking for a multipurpose, storage friendly, dynamic overland/camping lighting system that retains the nature of a vehicle mounted system while also gaining the benefits of a user-friendly portable product. With those needs in mind, this team created a portable light that mounts to aftermarket truck frames/bars, charges on vehicle power, and can be removed without the use of tools for use as a flashlight and will have a battery that can be serviced. Though removal is tool-less, it will have adequate anti-theft measures to not be stolen and will have sufficient thermal management to be safely held while utilizing as a flashlight, even after long periods of use. All functions are to be controlled by buttons. Overall, it creates an opening for Rigid to reach a new customer market and expand on their product growth and development.

 

EGR 402 Team 22: Alec Tran, Anthony Gant, Rohail Alvi, Xiaoyan Lin, Zachary Goode

Students: Alec Tran, Anthony Gant, Rohail Alvi, Xiaoyan Lin, Zachary Goode
Sponsor: ZEVX

ZEVX Logo


ZEVX Inc. is a company that converts vehicles powered by internal combustion engines into electrically driven vehicles. This team was tasked with creating a power distribution unit (PDU) that is designed to receive commands by the ECU and deliver power and signals to various subsystems of the vehicle. Due to the high demand of I/O connectors required and CAN-bus communication, an off-the-shelf PDU is not available with the given specifications. The PDU is also required to be waterproof to a minimum rating of IP67. This team’s solution is to build a PCB, software chip and mechanical enclosure to meet and exceed the given PRD specification.

 

EGR 402 Team 23: Cheng-Chi Tsai, Eduardo Gomez, Jacob Pfutzenreuter, Memphis Graham, Mikel Brodie

Students: Cheng-Chi Tsai, Eduardo Gomez, Jacob Pfutzenreuter, Memphis Graham, Mikel Brodie
Sponsor: NFPA Fluid Power Vehicle Challenge

NFPA Fluid Power Vehicle Challenge Logo


This team will compete in the Fluid Power Vehicle Challenge hosted by the National Fluid Power Association (NFPA) in Littleton, Colorado. The NFPA is an organization comprised of hydraulic companies that aim to educate college students on fluid power. The project will consist of the team revising and improving upon the fluid system of ASU’s fluid powered vehicle from the previous year’s competition. They will do so by changing hose lengths, hydraulic fittings, fluid control methods and the orientation of components, ultimately increasing the efficiency. Other vehicle components such as wheels, brakes, and a chain tensioner will be modified to increase vehicle safety and performance.

 

EGR 402 Team 24: Litzi Matancillas, Reagan Gillespie, Sai Srinivas Tatwik Meesala, Samir Strasser

Students: Litzi Matancillas, Reagan Gillespie, Sai Srinivas Tatwik Meesala, Samir Strasser
Sponsor: Isola Group

Isola Group Logo


The Isola Group is a global company that services the manufacturing industry by producing and supplying a range of products and raw materials. Their Chandler, Arizona, plant is designed specifically to produce copper-fiberglass laminate for PCBs with a focus on high-speed turnaround low-volume custom substrate. Isola’s current copper foil roll changeover solution is largely a manual process that takes two minutes which is longer than it should, decreasing their ability to fill out next-day printed circuit board (PCB) orders. Additionally, it currently can only hold two rolls and these two factors have become a bottleneck in the PCB material production line. This team has been tasked with designing semi-autonomous twin hoist system that can decrease the copper foil changeover time and remove the bottleneck in their line. The deliverables consist of a detailed mechanical and electrical design, a bill of materials (BOM) of the completed solution and a budget for a completed solution.

 

EGR 402 Team 25: Ethan Wittkopf, Giovanni Garcia Gaspar, Hendrik Cord

Students: Ethan Wittkopf, Giovanni Garcia Gaspar, Hendrik Cord
Sponsor: Mechanical Systems Startups, LLC.

Mechanical Systems Startups Logo


This team worked with Mechanical Systems Startups LLC to create a crash absorbing safety barrier. Prior eProject testing has demonstrated viability of a patented concept for a low cost crash absorbing safety barrier. This team’s assignment was to design and execute a subscale test (test cart weighing 250 lbs traveling at 20 mph) for an automotive crash safety barrier. Design effort includes tailoring barrier design to planned test conditions including ground anchoring. Testing includes measurements of displacement, velocity, acceleration, and pressures in the 10kHz range (i.e. some instrumentation or electronics knowledge needed on team). Consulting with ADOT and other agencies is desired.

 

EGR 402 Team 26: Jaren Flowers, Joshua Stanich, Kaijie Wang, Kyle Koliboski, Seth Wiley

Students: Jaren Flowers, Joshua Stanich, Kaijie Wang, Kyle Koliboski, Seth Wiley
Sponsor: Boeing

Boeing Logo


At Boeing Mesa, a team in their defense sector helps design and support the AH-64 Apache Helicopter. This team developed a lightweight, fully-autonomous capable drone frame utilizing cutting-edge additive manufacturing techniques. This drone, measuring at 2 ft. x 2 ft, is under 3 pounds. Additionally, the drone must incorporate all flight components in an optimal fashion, considering weight distribution and electrical interference.

 

EGR 402 Team 27: Dominick Vallelonga, Max Gao, Michael Femiani, Nicholas Johnson

Students: Dominick Vallelonga, Max Gao, Michael Femiani, Nicholas Johnson
Sponsor: Paragon Space Development Corporation 

Paragon Space Development Corporation Logo


Paragon Space Development Corp. (PSDC) has tasked this team to create an in-house motor control board to stop the need of outsourcing boards. The team has developed a motor control board for PSDC. The board will be used for testing space life support systems using different motors that will represent fans and valves. It is capable of controlling BLDC motors, stepper motors and solenoid valves to their full potential. The different actuators can be controlled through a user interface located on the test computer. The user can select the direction and speed for BLDC motors, direction and angle for stepper motors, and the state (open or closed) for solenoid valves.

 

EGR 402 Team 28: Aahan Venkatesh, Anthony DiFerdinando, Christian Torres, Tallin Speek

Students: Aahan Venkatesh, Anthony DiFerdinando, Christian Torres, Tallin Speek
Sponsor: ASU Center for Negative Carbon Emissions

ASU Center for Negative Carbon Emissions Logo


Each year, approximately 35 billion tons of CO2 is released into the atmosphere and if unaddressed, will cause irreversible damage to the environment. ASU’s CNCE is dedicated to reducing carbon emissions and reversing damage caused by carbon emissions before it is too late. To combat this, the CNCE uses Direct Air Capture (DAC) technology to capture CO2 from the air and store it for redistribution. The CNCE wants to build a portable direct air capture system that is self contained. This device will capture the carbon straight from the atmosphere and store it in a container through a compressor. The device is operated using pneumatic pistons that use carbon dioxide gas captured to push it up or down.

 

EGR 402 Team 29: Ian Mansfield, Jonathon Varela Chaparro, Justin Little-Sagg, Madelyn Molnar

Students: Ian Mansfield, Jonathon Varela Chaparro, Justin Little-Sagg, Madelyn Molnar
Sponsor: Honeywell Aerospace

Honeywell Aerospace Logo


This team worked with Honeywell Aerospace to create a unmanned aircraft system (UAS) critical crash system that will protect bystanders and buildings from small drones. The critical crash system the team is developing is a system that will detect when the drone is in free fall and will deploy an airbag and umbrella. The fall detection will be handled by a BNO055 IMU sensor sampling the z acceleration data and sending it to an Arduino Uno. The Arduino Uno will then detect from the acceleration if the drone is in free fall, where it will activate a servo to extend fans between the drone arms creating the umbrella and inflating an airbag below the drone.

 

EGR 402 Team 30: Austin Melancon, Daniel Espinoza Pena, Carlos Fajardo

Students: Austin Melancon, Daniel Espinoza Pena, Carlos Fajardo
Sponsor: Honeywell Aerospace

Honeywell Aerospace Logo


The future of urban transportation is rapidly evolving, with urban air mobility (UAM) vehicles poised to revolutionize how people move around cities. However, ensuring the safety and comfort of passengers during their journeys remains a critical challenge. One significant barrier is the high cost of electronic control units (ECUs) for HVAC actuation that are essential for regulating temperature and air quality in UAM vehicles. That’s where this team’s project comes in. They are partnering with industry leader Honeywell to develop a low-cost ECU that meets the unique needs of UAM vehicles. The team has identified key areas where Honeywell can reduce costs, such as leveraging automotive-grade technology, while still ensuring reliable and efficient HVAC control. Additionally, the modular design will make repairs and replacements easy and quick, reducing downtime and keeping UAM vehicles in the air where they belong. By addressing this critical challenge, the team hopes to enable the widespread adoption of UAM vehicles and make urban transportation safer and more accessible for everyone.

 

EGR 402 Team 31: Anthony Baldacci, Braxton Harris, James Zaverdas, Milan Patel

Students: Anthony Baldacci, Braxton Harris, James Zaverdas, Milan Patel
Sponsor: Honeywell Aerospace

Honeywell Aerospace Logo


This team was tasked with creating a digital twin of an aircraft subsystem for Honeywell Aerospace. The team decided to model a brushless direct current (BLDC) motor and electronic speed controller (ESC) in Simulink. The team fabricated their own printed circuit board consisting of a three phase inverter and circuitry to measure various parameters of the motor during operation. Using first principles and collected data from the physical system, the team generated an accurate digital twin of the BLDC and ESC. The motor controller along with the digital twin is all contained within a monolithic Simulink model. This model has provisions to compare the digital twin’s generated data to the hardware’s measured data.

 

EGR 402 Team 32: Charlotte Burns, Elizabeth Evans, Haylee Mastoris, Nicholas Giusti

Students: Charlotte Burns, Elizabeth Evans, Haylee Mastoris, Nicholas Giusti
Sponsor: Honeywell Aerospace

Honeywell Aerospace Logo


Thsi team partnered with Honeywell’s additive manufacturing lab. The goal of the project is to explore ways to increase sustainability in the lab, working towards Honeywell’s 2030 zero carbon emissions goal. The team is focused on defining the current additive manufacturing process that is used and exploring more sustainable resource options such as renewable energies. While also monitoring the life cycles of Argon gas and metal powders to see if there are any quantifiable losses that could be mitigated.

 

EGR 402 Team 33: Casey Whitson, Jeffrey Davis, Joseph Bauer, Logan Suffredini

Students: Casey Whitson, Jeffrey Davis, Joseph Bauer, Logan Suffredini
Sponsor: Honeywell Aerospace

Honeywell Aerospace Logo


This team partnered with Honewell Aerospace and their mentor Curtis Swift. The team tackled partially melted particles (PMP’s) that occur on the underside of 3D-printed parts while using metal 3D printing. To solve this problem the group selected a number of post-processing methods. These methods include electroplating, electropolishing, anodizing, abrasive slurry, and chemical milling. They aim to improve surface roughness and reduce free-flowing PMP’s inside oil/coolant passages.

 

EGR 402 Team 36: Adriana Juarez-Lara, Alexys Antell, Isaiah Begay, Niglan Quevedo

Students: Adriana Juarez-Lara, Alexys Antell, Isaiah Begay, Niglan Quevedo
Sponsor: Intel

Intel Logo


Intel’s primary interest in this project is the automation of their current flux dispensing procedure. The SLAM Flux Dispense Gun, envisioned as an automatic ball supplying gun, will formalize and standardize this dispensing process for Intel technicians who currently do it manually without the ability to control the flux volume, performance, and precision of the operation. This system will rid manual supply and remove any operator and human variables, allowing the overall process to be regulated and administered more exactly.

 

EGR 402 Team 37: Brandon Price, Caden Wyatt

Students: Brandon Price, Caden Wyatt
Sponsor: Endress Hauser IAC/Instrumentation And Controls, LLC

Endress Hauser IAC/Instrumentation And Controls, LLC Instrumentation and Controls, LLC


This team partnered with Endress and Hauser and Instrumentation and Controls to create a mobile simulation cart that is capable of demonstrating Endress and Hauser products and their IIOT (Industrial Internet of Things) features to customers. Endress and Hauser is a global leader in measurement instrumentation, services and solutions for industrial process engineering and provide innovative products and services to a wide range of industries. In order to achieve this demonstration of IIOT the team fabricated a mobile cart that will be able to display multiple Endress and Hauser sensors. The sensors will be connected to each other and a water tank via acrylic piping to best demonstrate the flow of water between the different sensors. Each of the sensors will be connected to the cloud via the Netilion so that customers can see the benefits of IIOT in real time.

 

EGR 402 Team 38: Juan Pablo Figueroa, Ryan Pak, Soohyeon Ahn

Students: Juan Pablo Figueroa, Ryan Pak, Soohyeon Ahn
Sponsor: Pepsico

Pepsico Logo


This team was selected to work on Lockout Tagout (LOTO) with Pepsico. The team created a training board to ensure the safety for new hires when working on the assembly line. They reviewed and audited current LOTO procedures of priority manufacturing line(s) and evaluated effectiveness. Then, they identified energy sources for LOTO procedures to implement a labeling method ensuring compliance to OSHA/PepsiCo standards.

 

Spring 2022 projects

FA22 eProject sponsored by Honeywell

Students: James Dick, Edward Montana, Alexander Skyriotis
Sponsor: Honeywell Aerospace

Honeywell


The batteries which are currently used in Honeywell’s power systems provide relatively short operational duration reducing mission efficiency and complicating mission planning and operation. Honeywell Aerospace aims to solve these problems by replacing the batteries of small UAVs with an advanced hydrogen fuel cell system capable of increasing operational duration by six to eight times. This team has been tasked with developing a temperature-controlled conduit for Honeywell’s hydrogen fuel cell system that must transport low humidity hydrogen to the fuel cell stack and high humidity hydrogen to the fuel cartridge without allowing water vapor to condense within the tubes.

 

Fa22 eProject sponsored by Collins Aerospace

Students: Jacob Beloat, Joel Seferian, Lucas Vasquez
Sponsor: Collins Aerospace

Collins Aerospace logo


Collins Aerospace, a unit of Raytheon Technologies Corp. is a leader in technologically advanced and intelligent solutions for the global aerospace and defense industry. This team has been tasked with automating a wire spooling process that is currently done by hand. Currently, a human operator loads a full spool and an empty spool then manually transfer the wire from one spool to the next. This manual process is both time consuming and dangerous. Using a UR5E Cobot, this team has made the spooling process safer for the operator and reduced cycle times.

 

FA22 eProject sponsored by Axon

Students: Jared Gates, Taylor Loslo, Roberto Rascon, Stephen Romero
Sponsor: AXON

axon logo


AXON specializes in drones and non-lethal methods of defense. Students were tasked with creating a perch and stare system for AXON’s taser drone to be located in areas where a greater risk for mass shootings are likely. Ideally, the device would incapacitate the threat with the taser drone that is in a perch and stare position and leave the drone in this monitoring position until law enforcement arrives. To fulfill this task, students created a mechanical claw that can grab onto objects on the ceiling.

 

FA22 eProject sponsored by Isola

Students: Lauren Castillo, Mikayla Castillo, Manuel Portugal, Manuel
Sponsor: Isola

Isola logo


This group was tasked with working closely with packaging and shipping employees at Isola’s USA corporation located in Chandler, Arizona. Using manufacturing principles, team members incorporated shelves and racks to improve workflow. A detailed training video and updated manual was also made to train new and current employees on how to work on the packaging line to relieve bottle necking.

 

FA22 eProject sponsored by Intel

Students: Miguel Cereceres, Zachary Shelton, Chantelle Taylor
Sponsor: Intel

Intel


Intel’s current demonstration setup has the potential to display more than it currently does and that’s where this team contributed their efforts. There is an opportunity to include Intel’s AI technology which currently works in a portable setup with multiple robots, several orientations and different camera angles. To address this, students created a lightweight, compact structure that showcases the MECA 500 robot moving different 3D printed objects on a conveyor belt. The team created a structure with camera and lighting mounts that can easily be moved to new locations to exhibit the flexibility of the AI technology. Ultimately, the team designed a transportable method for Intel to showcase their technologies.

 

FA22 eProject sponsored by Intel

Students: Alexander Austin, Jade Heun, Austin Jones, Lu Reh
Sponsor: Intel

Intel


The team is working with Intel to protect AMR electrical components against damage and malfunction at extreme temperatures (-40°C to 85°C) from issues such as condensation and boot up timeouts. To remedy this, students created a heating system for the AMR components using carbon fiber wire and a cooling system with refrigeration while monitoring humidity and temperature with sensors that are rated for those environments. The current lead-acid battery will also be switched out with a lithium-ion system to increase power efficiency.

 

FA22 eProject sponsored by Intel

Students: Mario Jacquez, Brett Kaiser, Seydrec Sloan, Adam Sparks
Sponsor: Intel

Intel


This team is working in conjunction with Intel to conceptualize and design an industrial Autonomous Mobile Robot, or AMR. Currently, there are no universal, scalable AMR chassis capable of holding various configurations and attachments on the market. Factories today have multiple AMRs specifically designed to tackle one task. With this in mind, students designed an AMR capable of completing a variety of tasks in the natural environment and industrial factories.

 

US Marine Corps 3rd Marine Expeditionary Force eProject

Students: Jacob Tarajkowski, Marco Torres, Benjamin Turner
Sponsor: U.S. Marine Corps 3rd Marine Expeditionary Force

US Marine Corps 3rd Marine Expeditionary Force logo


This team’s mission was to develop a joint-force, Universal Pod Loader, or UPL, capable of loading the HMAR, MSN and PATRIOT pods onto a CH-53 Super Stallion, VF-22 Osprey and CH-47 Chinook rotary wing aircraft that requires just two people to operate. Safety, environmental responsibility and affordability will be at the forefront of the design. They achieved this goal by producing a purely mechanical system that will use off-the-shelf components to streamline production and keep costs to a minimum.

 

FA22 eProject sponsored by Honeywell

Students: Michael Mirabito, John Sharpe, Joshua Steverson
Sponsor: Honeywell Aerospace

Honeywell


Honeywell is one of the world’s leading manufacturers and has leveraged the powerful technology of additive manufacturing to create complex components in the aerospace and defense industries. One important application of this technology has been manufacturing heat exchangers. Traditionally, these parts are difficult to make, time-intensive, and costly. Honeywell looked to additive manufacturing to solve this problem and began manufacturing heat exchangers using metal 3D printing technology. By transitioning to additive, Honeywell was able to rapidly produce heat exchangers that are more efficient, reliable, and durable. To better understand this technology, Honeywell tasked this team with creating with a DFAM project, or Design for Additive Manufacturing, to redesign an existing Ford oil cooler to be more effective, contain less parts and be optimized for 3D printing.

 

Innovation Showcase

Students: Wyatt Ringwald, Luke Hagaman, Raney Pate


The goal of this project was to design and explore the Venturi effect.

 

Fall 2022 projects

EGR 402

Students: Michael Jodat, Alejandro Manzo, Jason Mester, Holden Mitchell

Sponsor: Zero Electric Vehicles

Zero Electric Vehicles

 

 

 

 


Zero Electric Vehicles, or ZEV, requested an auxiliary system for a vehicle that converts the suspension’s potential energy into usable electrical energy. ZEV specializes in the conversion of internal combustion fleet vehicles into fully electric vehicles. ZEV hopes to utilize a suspension harvesting system in their converted vehicles to improve their efficiency. The team took a mechanical approach to address this issue. They utilized a lever arm attached directly to the vehicle’s suspension, which is connected to a bidirectional to unidirectional gearbox. That gearbox is then connected to an electric power generator which can charge the vehicle’s low voltage system.

 

EGR 402

Students: Whitney Foster, Anson Kwan, Jiangtao Li, Aurausp Maneshni, Shannon Mcbreen, Michael Schelp, Isabelle Thalman, Ziyu Wang

Sponsor: Siemens

Siemens

 


The manufacturing industry has experienced rapid technological growth and is moving from industry 3.0 technology to industry 4.0 technology. This growth is leaving behind a workforce without the skills to meet the demands of this new technology and as a result has created a significant labor shortage. Team 18 – 19 has partnered with Siemens and Jerry Gintz, professor of engineering at The Polytechnic School, to refurbish a manufacturing workstation. The workstation aims to serve as an educational manufacturing device that upskills students before they enter the workforce so they have the opportunity to master various industry 4.0 competencies. This solution also has a digital twin component to meet a wide variety of potential user learning needs.

EGR 402

Students: Rocco Francone, Lance Grotelueschen, Michael Mcnerney, Connor Montalban

Sponsor: Discount Tire

Discount Tire

 


Team 25 has been working with Discount Tire to develop a solution that can effectively remove the residue left on wheels by tape weights. The residue leaves behind an irregular surface that not only creates a dirty appearance, but also prevents effective surface bonding between the wheels and additional tape weights. The solution that Team 25 developed is a rounded-edge eraser tool attachment with a quick-change mandrel. This tool piece is designed to allow service technicians easy access to the interior surfaces of wheels for the residue removal, while also being compatible with different types of tooling for effective use.

 

EGR 402

Students: Brayden Dean, Hector Espino, Xingchen Li, Anthony Manriquez

Sponsor: Discount Tire

Discount Tire

 


This team worked with Discount Tire and confronted existing tooling issues. Discount Tire stores currently use a plastic scraper which dulls quickly and eventually becomes ineffective. Students of this team designed a tool with a replacement medium that is more durable and more effective at removing the weights. The group is currently testing two solutions, with a string or composite blade.

EGR 402

Students: Kye Arias-Burmood, Isaac Enriquez, Bradley Gannon, John Lewis

Sponsor: NASA Psyche Mission

NASA Psyche Mission

 

 


ASU Psyche is an ASU-led NASA mission to the asteroid Psyche-16 that is believed to be the remains from a planetary core. This team’s task is to create a system that would be able to sample the hypothesized surfaces for further research of planetary cores. They designed a device consisting of a drill motor attached to a linear actuator with accompanying sensors that will drill down through the surface to collect a sample. The major component of the team’s system is a custom designed drill bit with openings throughout and a hollow core for sample collection and containment.

 

EGR 402

Students: Tyler Jiemback, Austin Kipp, Andrew Meiners, Zach Schley

Sponsor: Lallemander Baking Solutions

Lallemand Baking Solutions

 

 


Lallemand, a yeast manufacturing company, tasked this group with implementing a palletizing robot into their facility, redesigning the production line and implementing real-time data collection. Currently, workers are palletizing 50-pound bags and boxes for 8+ hours per day leading to negative long-term health impacts. This solution is needed to assist the workers and maintain consistent output rates. The team is also redesigning the production line and implementing a system to track the speeds of the conveyors, rejected product quantities and overall weights of the bags and boxes.

 

EGR 402

Students: Seth Forbis, John Socaciu, Tyler Von Ende

Sponsor: Honeywell Aerospace

Honeywell

 


This team partnered with Honeywell to investigate the manufacturing process of reaction wheel assemblies, or RWAs, used in precision satellite positioning and alignment. As a provider of premium hardware built to last, the industrial partners manufacturing process requires precision machining and quality testing for their RWAs. The team’s goal is to identify machinery capable of replacing manual processes while maintaining or improving upon the quality of RWAs produced. The solution was to survey a wide array of companies providing manufacturing equipment and to select the best technology for this process.

 

EGR 402

Students: Petros Magoulas, Roberto Siqueiros, Clark Vidler

Sponsor: Honeywell Aerospace

Honeywell

 


This project was proposed by Honeywell Aerospace, an avionics firm interested in exploring the capabilities of semi-autonomous commercial flight. Pilots are currently an indispensable but costly component of commercial passenger flight. While unmanned aerial vehicles already exist, FAA regulations and a general mistrust by the public currently prevent their use in passenger flights. This project aims to explore a possible stepping stone between an autonomous future and the present, where a pilot in the cockpit operates the aircraft alongside a telepresence co-pilot. This co-pilot observes the cockpit through stereoscopic cameras with pan and tilt capability. The cameras will also provide insightful vision analytics of dashboard instruments and other important signals to allow the co-pilot to make quick and informed decisions.

EGR 402

Students: Isabella Bushroe, Maison Carey, Jordan Johnson, Gino Piccino


Phoenix Sky Harbor Repair and Overhaul Factory currently uses aluminum tape to mask many of the parts they re-work. This process is time consuming and tedious. This team is creating reusable, custom-fit masking solutions for two of their commonly repaired parts, a blade and a nose cone. They are 3D printing molds out of PLA and filling them with flexible polyurethane. The resulting polyurethane components will fit closely over parts of the blade and nose cone to protect them from paint and grit blast. These will reduce repair time and increase productivity.

 

EGR 402

Students: Christopher Brisco, Trenton Clark, Samuel Martin

Sponsor: Paragon Space Development Corporation

Paragon

 


This team is designing and testing a space rated DC-DC converter using GaN FETs. Due to cost and time constraints, their test design will be created using non-space rated components that have space rated counterparts. The students are working with Paragon Space Development Corporation, a company that works with other space and defense companies including NASA. Their solution is a converter with a flyback topology based on its widespread use and the limited number of components compared to other topologies.

EGR 402

Students: Andrew Crouch, Ameil Jones, Hikmat Lawal, Fabian Siqueiros

Sponsor: Intel

Intel

 

 


This team partnered with Intel to develop a modular architecture of an autonomous mobile architecture, or AMR. The scope of the project is to develop a simulation by using MatLab of AMR mobile architectures that allow for various reconfigurations. Along with developing data analysis using Arena, that provides throughput capabilities such as how many models would it take to complete a task, the project includes cycle time — analyzing how long it takes a model to complete a task and how the throughput and cycle time changes between one model and another.

 

EGR 402

Students: Damion Fedler, Aaron Matejcik, Cole Rose, Andrew Sheehan

Sponsor: Northrop Grumman

Northrop Grumman

 

 


This diverse team of mechanical and automotive systems engineering students has partnered with Northrop Grumman’s launch and missile defense systems in Chandler, Arizona, to develop a new rotary actuator test stand. The stand is used in Northrop’s acceptance testing procedures to validate the hardware that supports their portfolio launch vehicles. The company’s existing equipment is quickly reaching the end of its functional life and services only a fraction of the actuators they use. Through a broad range of inertial, torsional and other design constraints, this team has developed a modular prototype that will not only encompass Northrop’s current stock but allow for modifications for future business needs.

 

EGR 402

Students: Maria Espinoza, David Oberan, Alezzandro Ortega, Hailey Suh

Sponsor: Honewell Aerospace

Honeywell

 


The Honeywell Modeling the Factory of the Future capstone project was tasked with developing a digital twin of the T55 engine repair and overhaul line, using Siemens Process Simulate. The objective of this project is to assist Honeywell employees in shortening the learning curve it takes to master the software and build an operational model. The team has provided a process simulate model displaying the assembly process of the T55 rotor compressor assembly. This deliverable includes a methodology that acts as a training guide to understanding process simulate. The methodology includes step-by-step instructions on the fundamentals of building a simulate model as well as information on the interactive human kinematic capabilities available.

 

EGR 402

Students: Angelica Lugo, Kaycee Simpson, Kevin Wagner, Avery Wallace

Sponsor: General Dynamics

General Dynamics

 


This team is working with General Dynamics – Mission Systems to innovate a solution to the existing problems with miniaturized variable heat conductance pipes on a payload equipment designed for space flight. The team took the existing VCHP design and worked on creating a new VCHP design with new materials to find a solution. The team also created a test bench to house the VCHP design, modeled an ANSYS simulation based on the VCHP design to theorize thermal behaviors and will conduct TVAC and dynamic testing in the General Dynamics lab to conclude if the new VCHP design is a successful solution to the problem identified.

 

EGR 402

Students: Serena Baca, Brandon Rojas, Konner Shook, Anthony Tutherow

Sponsor: Honeywell Aerospace

Honeywell

 


With the proliferation of technology today, the potential of extremist groups to use things like drones to deliver dangerous ordinances is a possibility. Along with Honeywell, this team’s goal is to create a man portable armor system that can adapt to a wide range of drones with the intent to take down small hostile drones. They will attempt to accomplish this by 3D printing an armor that mounts on the front of rear motor propelled drones as a basis to focus impact while minimizing the impact for the drone.

 

EGR 402

Students: Kiley Griffin, Justin Janda, Ian Martin, Nathan Neville

Sponsor: Mechanical Systems Startups, LLC

Mechanical Systems Startups LLC

 


The current market of crash safety barriers does not significantly reduce the impact of a crash as they rely on deflection. Mechanical Systems Startups, LLC, has modeled and simulated a crash safety barrier that absorbs the impact and disperses the energy. This team has been tasked with validating these models with a quarter-scale test. They have modified the ASU Hyperloop test track and the test vehicle to complete this testing. The data should validate the models so that further testing can begin.

 

EGR 402

Students: Turki Almudbil, Jose Espinoza, Matthew Jarrell, Priscilla Ramirez

Sponsor: NXP Semiconductor

NXP semiconductor

 


This team was tasked with designing an ergonomic solution for loading stainless steel domes containing semiconductor wafers onto a metal evaporator process tool for NXP Semiconductor. NXP has multiple wafer fabrication facilities across the world and is a major supplier for the semiconductor industry. The team designed a vertical lift which was made from stainless steel and aluminum. It operates via a cam belt linear drive system. The goal of his design was to increase NXP workplace efficiency and safety, while also maintaining the company’s wafer quality.

 

EGR 402

Students: Peter Gregus, Ryan Hyatt, Armando Ramirez, Alejandro Yescas

Sponsor: United States Air Force


The JSTARS is a fleet of highly modified Boeing 707’s maintained and flown by the United States Air Force. One routine JSTARs maintenance procedure is the removal and replacement of the disk brake assembly on the landing gear. This assembly weighs close to 200 pounds and poses a risk of injury to the crew during the removal and installation process. The USAF has requested a tool that can safely and efficiently lift the brake assembly. Team 10 has engineered a hoist that features a simple and robust design that can be adapted to several airframes for brake removal processes.

 

EGR 402

Students: Alexander Olsen, Riley Schaefer, Michael Skalsky

Sponsor: TPI Composites

TPI composites

 

 

 


This team worked with TPI Composites to construct a system capable of taking pictures of a windmill blade cross section, then take measurements based on those pictures. Once each cross section is measured, the measurements are used to construct a 3D model of a completed windmill blade. The purpose of this task is to reduce the amount of time needed to measure the windmill blade and thus increase the rate that windmill blades are produced. The team used a gantry system capable of moving a camera over a cross section — taking pictures of the blade as it traces the perimeter of the blade to capture a measurement.

 

EGR 402

Students: Alexander Burck, Kevin Crowley, Cole Mcduff

Sponsor: Honeywell Aerospace

Honeywell

 


Honeywell has recently transferred a testing facility to their avionics manufacturing site in Deer Valley, Arizona. Due to environmental differences, the relocated test chambers periodically experience undesirable moisture levels during operation. This team was tasked with restoring and ensuring a controlled screening environment. They developed a cost effective, automated and non-invasive SCADA system that easily integrates with existing infrastructure. Functionally, the device detects critical events and appropriately delivers CDA, while communicating with a central hub.

 

EGR 402

Students: Cortney Batt, James Seifert, Liam Snider, Spencer Wheat

Sponsor: Honeywell Aerospace

Honeywell

 


This team partnered with Honeywell Aerospace to investigate a production improvement study in their thermal spray process at the Honeywell maintenance, repair and overhaul, or MRO, facility. Honeywell currently uses aluminum tape and silicone putty to protect areas of jet engine components not requiring metal spray application. The tape and putty process is a time-consuming hand operation that Honeywell would like this group of students to improve from a time and simplicity standpoint. The team will explore the possibility of creating hard-shelled, high-temperature refractory masks using Honeywell’s internally developed 3D printed ceramics to replace the tape and putty.

 

EGR 402

Students: Taylor Bollinger, Payten Chicci, Jax Jimenez-Jones

Sponsor: Discount Tire

Discount Tire

 


This team was tasked with designing and creating a new air chuck for Discount Tire. The two current air chucks have problems they hope to remedy in order to be more efficient and cost-effective. The main concerns they have with these chucks are that they wear easily and the same type of chuck cannot be used on every type of vehicle rim. Some rims, seen on trucks in particular, have recessed valve stems that can be hard to insert the air chucks into. This team have created a shorter, more durable and reliable air chuck that aims to solve these issues.

 

EGR 402

Students: Logan Garland, Emmanuel Machado, Eden Ochoa Ramos, Nicole Van Handel

Sponsor: Honeywell Aerospace

Honeywell

 


Honeywell Aerospace conducts the maintenance, repair, and manufacturing for aircraft in the public and private sectors. Repair processes for complex parts, such as impellers, rely on CMM and proprietary programs which there is decreasing expertise in. There is an opportunity to modernize and streamline the scanning, digitization and toolpath creation process, making it broader and more adaptive. In collaboration with industry partners Jason Floor and Dr. Ben Peterson, Team 45 has developed an updated process that utilizes structured light scanning and Siemens NX to adaptively determine repairability of parts and generate machining toolpaths based on scans.

 

EGR 402

Students: Jason Dabney, Zachary Schwartz, Hunter Silvey

Sponsor: Andersen Windows and Doors

Andersen Windows and Doors

 


Team 13 partnered with Andersen Windows and Doors to help them solve the problems they are experiencing with their french door assembly workstation. Their current workstation has inefficient cycle times, places stress on the workers due to poor ergonomics and damages the surface of doors that are built on it. This team’s solution is a redesign of the ergonomic flow of the station by modifying the dimensions of the table, adding an extension component that is self supporting and creating a table surface that protects the product.

 

EGR 402

Students: Jacob Delacruz, David Harden, Jerred Hermogino, Akhil Johnson, Hala Mayyas, Andrew Peavler, Matthew Seddon, Logan West

Sponsor: National Fluid Power Association

National Fluid Power Association

 

 

 

 


The National Fluid Power Association (NFPA) tasked this group with fabricating and improving a trike that consists of an integrated hydraulic power system to compete against multiple universities in the Fluid Powered Vehicle Challenge (FPVC). The design objective is to design, build, test and validate a human-powered hydraulic trike that will achieve a speed of at least 10 mph at a maximum weight of 210 pounds. The team’s solution is to integrate, while meeting competition design constraints, a human powered trike while utilizing a hydraulic power system to propel the wheels.

 

EGR 402

Students: Jessica Dirks, Brooklyn Johnson, Bridget Koehl, Spencer Sillanpaa

Sponsor: Becton Dickinson

Becton Dickinson

 

 


In this project, sponsored by Becton Dickinson, students have teamed up to explore avenues for introducing new innovative twists into a traditional medical device. Over the course of the project, the team was asked to undertake the following tasks: Evaluate current technology and techniques of production, identify appropriate needs to address and integrate the solution into a prototype to demonstrate successful operation.

 

EGR 402

Students: Mohammed Bawareth, Deborah Eisenberg, Wendy Lara, Rebekah Wagen

Sponsor: IDEA Lab

IDEA Lab

 


Becoming educated in STEM fields during high school and secondary education isn’t common. Daniel Aukes, assistant professor of engineering at The Polytechnic School leads the IDEA Lab and has hopes to change that. Team 14 has been working in conjunction with Aukes to develop a five-day summer camp geared towards students aged 11-13. The camp will teach a basic introduction to electronics, programming and how robotics relate to biology. Using the knowledge obtained in the camp, students will be able to construct their own foldable robot that will be presented on the final day of camp.

 

EGR 402

Students: David Altamirano Leon, Samuel Andersen, Marcus Dopilka, Nathan Fonseca

Sponsor: Able Aerospace Services Inc.

Able Aerospace

 

 


This team partnered with Able Aerospace Services Inc., a company that provides resourceful component repairs, overhaul and approved replacement parts solutions for aircraft operations. Students were tasked with validating manufacturing repair techniques for worn or damaged aluminum components. They are also assisting Able Aerospace in validating their state-of-art repairing methodologies using cold spray and shot pen and show an increase in the fatigue life of the aluminum samples. The long term goal is to use this new method and meet the Federal Aviation Administration (FAA) regulation with a more cost-effective repair methodology.

 

EGR 402

Students: Lee Brown, Joseph Bruder, Adrian Ramirez, Edward Taylor

Sponsor: AbTech Industries

AbTech Industries

 

 

 


AbTech Industries is a company dedicated to the treatment of wastewater, whether that be in the form of industrial runoff water or storm water. Monitoring the state of any given storm drain filter around the world through a cloud network of IoT sensors is of substantial interest to AbTech Industries. To address this, this group of students developed a solution that uses load cell sensors and ultrasonic sensors. The load cells are used to measure the weight of the filter and the ultrasonic sensor is used to determine whether or not there is standing water in the UUF box created by clogging. These sensor readings are managed by a microcontroller and sent to a WiFi module.

 

EGR 402

Students: Sergio Ramos, Jun Kai Yeo

Sponsor: Summit Automation

Summit Automation

 


Team 11 Base Motor (Vail Motor) worked with Summit Automation to develop an upgrade to their current door animation system. The problem with their current door automation system is the high cost and extensive installation process. This combination makes their product not accessible to the elderly which are the target audience. Students worked on developing a safe, low cost and easy to install solution by using a smaller motor that can fit in the frame of any door to make it more accessible.

 

EGR 402

Students: Faisal Alyousif, Matthew Gargan, Rachel Hayden, Richard Nguyen

Sponsor: Heitek Automation

Heitek Automation

 


Heitek is an independent company located in Phoenix, Arizona, and distributes automated systems. Heitek’s various vendors and suppliers had products they wanted showcased through Heitek, however, the company did not have a system built to display product integration or showcase those products’ capabilities. To address this concern, Heitek Automation and ASU partnered to design and develop a demonstration featuring a three-axis machining center. Utilizing approximately $30,000, the teams’ goal revolved around implementing different control systems and displaying how they interact with one another to both train employees and educate customers.

 

EGR 402

Students: Isaiah Finney, Shams Hassan, Simon Pavlick, Jorge Perez

Sponsor: Moog Broad Reach

Moog Broad Reach

 

 


Team 32 is worked with Moog Broad Reach to bring automated optical inspection, or AOI, to the PCB production line. Their aim is to incorporate a new inspection system into the current infrastructure found at Moog’s workspace, effectively reducing the time for inspections from hours to minutes. The existing circuit boards can have up to 1400 components per side and are currently inspected manually by technicians — some of these components can be as small as a grain of sand and require a microscope. The team ensured AOI was properly installed into the production line and that there was labor required to ensure the quality of the manufactured board was maintained.

 

EGR 402

Students: Jeremy Batson, Alexandria Bisher, Bryan Carlton, Nicolo Hamilton

Sponsor: NXP Semiconductor

NXP semiconductor

 


At NXP Semiconductors the current process of moving lot boxes onto the storage rack is inefficient as it takes one person two minutes per box to move them from the AMHS stocker to the storage rack. NXP requires a robot that moves the boxes to the storage rack, safely, so that associates may simply grab the box from the rack. This team designed a robot that will take the lot boxes from the output port of the AMHS stocker and store the lot boxes on a staging rack. This will allow the associate on the factory floor to quickly take lot boxes from the staging rack to the machines saving the company valuable time.

 

EGR 402

Students: Awab A Salam Mohamed, Jay Godin, Borna Mansoormoayad, Aaron Saltou

Sponsor: The Air Force Research Laboratory


The Air Force Research Laboratory has proposed a challenge for university students to develop a prototype for a backpackable, covert and highly mobile device. The main purpose of the device is for moving supplies over rough and rocky terrain from one location to another. During a variety of missions, there are circumstances where troops require supplies from other members of their team. This team designed and prototyped an unmanned aerial system to perform this task. The UAV utilizes coaxial flight techniques for efficiently generating the maximum thrust.

 

EGR 402

Students: Eric Elkassab, Granville Smith, Malcolm Smith, Malik Townsend

Sponsor: Raytheon Technologies

Raytheon

 


In Raytheon’s factories and warehouses they use automated guided vehicles, or AGV’s, used to transport loads within their facilities without human interactions. They are looking for their AGV systems to be more efficient and more environmentally friendly by reducing the wear and tear of the AGV’s suspension system. This team was tasked with providing a prototype AGV suspension system for the company to adapt into their current system that will allow them to be more efficient by reducing slippage on factory floors, reduce cost of maintenance, increase stability over uneven floors and bumps and to be able to carry a load of 500 pounds.

 

EGR 402

Students: Marshall Botta, Erick Duarte, Derek Marshall

Sponsor: Raytheon Technologies

Raytheon

 


This team worked with Raytheon Technologies to develop a mechanical system that will allow an automated guided vehicle, or AGV, to dock consistently and reliably. The students’ target tolerances are +/- 4 mm in the x and y dimensions and to be within +/- 1 degree of perpendicular. For the sake of simplicity, they developed strictly a mechanical system. The cart they used to simulate an AGV will successfully dock only when it is within the target position. Undocking the cart is done with the aid of two pneumatic air cylinders.

 

Summit Automation

Students: Trenton Gutowski, Kyle-Christopher Kelley, Brittany Tews

Sponsor: Summit Automation


This team worked with Summit Automation, a company specializing in the design and manufacturing of automated doors and windows, to design a new and improved version within one of its already existing product lines. The product is a wall “switch” that provides a user interface between the customer and their Summit Automation automated doors/windows. Previous versions of this wall switch were either too basic (mechanical) or too unrefined (missing features) for the company’s product goals. Summit’s customers desire a more sleek design that blends in rather than stands out in their home or office. This team’s solution is a touchscreen with a minimal bezel, featuring multiple menus for setup or installation and operation. The design also features motion sensing, light sensing, background customization and wireless control via WiFi.

 

Honeywell

Students: Micah Nagel, Jeffrey Papesh-Jacobs, Bella Recato, Avery Wenta

Sponsor: Honeywell Aerospace


Honeywell Aerospace partnered with this team to determine if their aircraft products could be made lighter utilizing a material called shape memory alloys, or SMA’s. The team was tasked with discovering a replacement to one of its heavier components, the solenoid valve. The solenoid valve is currently their most common form of actuation used in commercial and military aircraft and the chosen component to be innovated upon. The goal is to improve system optimization to conclude whether or not Honeywell should continue to develop this technology. The team is seeking a patent for using resistive heating to actuate the SMA and operate the valve.