Summary for Spring 2017

Department:

Total Records: 128



Projects for Spring 2017

CompanyProject TitleInstructorCourseAgAeroBMEChECMPSCCMPENGEDGEnergyESMEEIEMATSEMENucEConf.IP
1ArcelorMittalMechanical Cold Expansion of Drilled Bolt Holes - Team 1Campbell, RobertME 440W.5







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2Armstrong World Industries 1Ceiling Tile Perimeter Mapping and Cutting System - Team 1Bilen, LennartCMPEN 482



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3Armstrong World Industries 2Ceiling Tile Perimeter Mapping and Cutting System - Team 2Campbell, RobertME 440W.5



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4AudioGoMiniaturized wearable audio recorderWheeler, TimEE 403.1&2




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5B. Braun Medical3D HYBRID METAL ADDITIVE MANUFACTURING for MOLD CAVITIESHayes, DanBME 450.2

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X X
6Bechtel Plant Machinery IncPersonal Electronic Device Climate Controlled ContainerWheeler, TimEE 403.1&2




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7Bechtel Power CorporationHeat Exchanging System for Fusion Power ReactorKnecht, SeanEDSGN 460





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8Bedford Reinforced Plastics IncPROCESS IMPROVEMENT IN MIXING AREAImmel, MichaelIE 480W




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9Bridge Gap Engineering, LLCPositive Displacement Air SealEser, SemihEGEE 464






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10Bridgestone Americas Tire OperationsTire mounting support for Semi-Anechoic Chamber load frameCampbell, RobertME 440W.5











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X X
11Capital OneTransferring Money via Amazon EchoVerbanec, AlanCMPSC 483



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12Central PA SCI Support GroupSafe Snowboard Binding for Triple AmputeeRitter, SarahBME 450.1

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13ChartlyticsWearable behavior counting deviceBilen, LennartCMPEN 482

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14CIU#10 and Easter SealsEaster Seals Sensory RoomBilen, LennartCMPEN 482



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15CO Film SocietyBoulder International Film Festival – Streamlining Operations Behind the ScenesPurdum, CharlieIE 480W









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X
16DiamondBack Truck CoversImproving ergonomics in material handlingRothrock, LingIE 480W









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X


17Discovery Space 1Augmented Reality SandboxBilen, LennartCMPEN 482



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18Discovery Space 2Value Engineering at Discovery SpaceCannon, DaveIE 480W









X




19Dresser-Rand, A Siemens Business 1Centrifugal Impeller Axial Movement Study - GLOBAL PROJECT WITH SJTUNeal, GaryME 440W.2










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20Dresser-Rand, A Siemens Business 2Printed Parts for Test RigMenold, JessME 440W.7









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21Dresser-Rand, A Siemens Business 3Rotatable Return Channel VanesPerez Blanco, HoracioME 440W.4









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22Dresser-Rand, A Siemens Business 4Non-Metallic Impeller Eye Labyrinth SealsKimel, AllenMATSE 493










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23Dresser-Rand, A Siemens Business 5High Pressure Case SealLynch, StephenME 441W










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24Dresser-Rand, A Siemens Business 6aOWC Turbine Mounting- Team 1Eser, SemihEGEE 464






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25Dresser-Rand, A Siemens Business 6bOWC Turbine Mounting - Team 2Eser, SemihEGEE 464






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26FedEx ServicesPrototype next-generation sort applicationVerbanec, AlanCMPSC 483



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X X
27Flowserve Corp.Waste Heat Energy RecoveryLynch, StephenME 441W






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28Ford Motor Company 1Ford Robot Vision IntegrationWheeler, TimEE 403.1&2



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29Ford Motor Company 2Evaluation and Optimization of a Press Die Pad Balancer DesignLewis, ScottME 440W.8











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30Ford Motor Company 3Optimized Rear Folding Vehicle SeatLewis, ScottME 440W.8







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X


31Ford Motor Company 4Autonomous Vehicle InteriorErdman, MichaelE SC 497







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X


32GKN Aerospace Engine SystemsResearch and develop additive manufactured bladed disks - GLOBAL PROJECT WITH CHALMERSMoore, JasonME 440W.1







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X
33HC StarckWet Etching Trials on Multi-Layer Metallic Films for Display TechnologiesKimel, AllenMATSE 493










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X X
34Horizon Signal TechnologiesSolar Panel Tilt & Rotate - GLOBAL with The Belgium Campus (S. Africa)Erdman, MichaelE SC 497




X X X X X

X


35Hyundai America Technical Center, Inc.Design and Evaluation of BISG Supervisory Control AlgorithmPerez Blanco, HoracioME 440W.4



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X
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X


36John Crane Inc.Automatic heating rig for Polymer element assembly process - GLOBAL PROJECT WITH SJTUJefferies, RhettME 440W.3











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37John DeereFlexible Piping for Diesel Exhaust Systems 2Lewis, ScottME 440W.8











X


38LB&A Consulting Group, LLCMaking music with 3D printed drumsticksKnecht, SeanEDSGN 460




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39Lockheed MartinRF ID Keyed GateVerbanec, AlanCMPSC 483



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40Lord CorporationDesign of A Bumper - GLOBAL PROJECT with SJTUNeal, GaryME 440W.2







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41Lycoming EnginesStarter Ring Gear Support Design and AnalysisPerez Blanco, HoracioME 440W.4







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42Marathon Petroleum CompanyAbove Ground Storage Tank Static Electricity and Lightning Mitigation - Phase 2Eser, SemihEGEE 464




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43Night Vision and Electronic Sensors Directorate (NVESD) 1Feed Tray Cover Shock SimulatorRay, AsokME 440W.6



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44Night Vision and Electronic Sensors Directorate (NVESD) 2Tank Motion Simulator Verbanec, AlanCMPSC 483



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45Penn Machine Company 1Design of Mechanically Fastened Rail Road WheelsPerez Blanco, HoracioME 440W.4











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46Penn Machine Company 2Design of Wheel Sensors to Monitor Railroad Wheel HealthWheeler, TimEE 403.1&2





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47Philips Ultrasound 1Vertical Lift Module Inventory OptimizatioinPang, GuodongIE 480W









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48Philips Ultrasound 2Factory Material Movement and Transaction OptimizationPang, GuodongIE 480W









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49PSU Alumni AssociationPSAA Production Process AnalysisPang, GuodongIE 480W









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50PSU BME 1Dev. of a simulated flow environment for nanoparticle delivery to atherogenic endothelium - GLOBALHayes, DanBME 450.2

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51PSU BME 2Dev. of a cardiac fluid flow analysis system to study fluid dynamic in carotid artery stenosi-GLOBALRitter, SarahBME 450.1

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52PSU Children's HospitalLow-temperature plasma sterilization of medical equipment: the Sorin 3T Heater/CoolerHayes, DanBME 450.2

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53PSU CIMP-3D 1Design and Prototyping of an Improved Powder Feeder System for Additive ManufacturingRay, AsokME 440W.6









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54PSU CIMP-3D 23D Printing at SeaCampbell, RobertME 440W.5









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55PSU CIMP-3D 3Lightweight Quadcopter: Novel Designs Enabled by Metal Additive ManufacturingCampbell, RobertME 440W.5




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56PSU Dept. of ArchitectureDesigning a System of Prefabricated Parts for ADA-compliant Residential Wheelchair RampsMenold, JessME 440W.7





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57PSU Engineering Leadership DevelopmentBaobab Pulp ProcessorImmel, MichaelIE 480W





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58PSU eSportbikePSU eSportbike: Motor & ControlsEser, SemihEGEE 464






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59PSU Fleet OperationsPSU Fleet Operations Efficiencies ImprovementsPurdum, CharlieIE 480W









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60PSU GridSTAR Center 1Net Zero Tiny House Trailer Team 1Eser, SemihEGEE 464





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61PSU GridSTAR Center 2Net Zero Tiny House Trailer Team 2Eser, SemihEGEE 464





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62PSU Hershey Medical Center 1Precision endoscopic suturing deviceRitter, SarahBME 450.1

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63PSU Hershey Medical Center 2Endoscopic Ultrasound Guided Radiofrequency Ablation Probe for Pancreatic CancerErdman, MichaelE SC 497

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64PSU IME 1Development of a Variable Diameter Nozzle for 3D PrintingCannon, DaveIE 480W



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65PSU IME 2Development of a Variable Diameter Nozzle for 3D PrintingCannon, DaveIE 480W



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66PSU IME 3Design and possible implementation of Lego FactoryRothrock, LingIE 480W









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67PSU IME 4Internet of Things Enabled Legacy MachinesRothrock, LingIE 480W









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68PSU IME 5Automated Lab Safety SystemImmel, MichaelIE 480W









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69PSU Institute for CyberScience 1Portable Computation Display WallBilen, LennartCMPEN 482



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70PSU Institute for CyberScience 2Repurposing Decommissioned ICS ClustersVerbanec, AlanCMPSC 483



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71PSU Institute for Natural Gas Research 1Carbon Index and Real-time End User Carbon Measurements - Team 1Eser, SemihEGEE 464



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72PSU Institute for Natural Gas Research 2Carbon Index and Real-time End User Carbon Measurements - Team 2Eser, SemihEGEE 464



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73PSU Made by Design Lab 1Design of an Adaptable Ejection Mechanism for a 3D Printing Vending MachineRay, AsokME 440W.6





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74PSU Made by Design Lab 2Design of a Filament Recycling System for Polymer 3D PrintingRay, AsokME 440W.6





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75PSU MatSE DepartmentUser equipment control and logging software developmentVerbanec, AlanCMPSC 483



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76PSU MechatronicsChest Band Energy HarvestersMenold, JessME 440W.7




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77PSU MNE 1Design and Development of A Closed-Loop Metal AM SystemRay, AsokME 440W.6




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78PSU MNE 2Development of Design-Fabrication-Testing Work Flow for Custom Shoulder JointsLewis, ScottME 440W.8

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79PSU MNE 3Designing DIY Kits to Produce Life-Saving Materials in Response to the Global Water CrisisKnecht, SeanEDSGN 460


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80PSU MNE 4MACS Lab: Monitoring and control of 5 and 10kW electromagnets using LabviewWheeler, TimEE 403.1&2








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81PSU MNE 5Pulling Water from Thin Air: Design and Characterization of a Portable Fog-Harvesting MachineKimel, AllenMATSE 493








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82PSU MNE 6Handheld Tribometer to Measure Slip Resistance of FlooringLewis, ScottME 440W.8



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83PSU Nittany Lion Inn 1Kitchen Operations ImprovementPurdum, CharlieIE 480W









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84PSU Nittany Lion Inn 2Whiskers Operations ImprovementPurdum, CharlieIE 480W









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85PSU Office of Research Information Systems Analyze System Email Notifications from Research Administration SytemsPang, GuodongIE 480W





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86PSU Origami EngineeringOrigami Engineering: Automation of a 3D printing platform using LabviewWheeler, TimEE 403.1&2








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87PSU PennTAPReal-time On-Site Energy Assessment Report GenerationEser, SemihEGEE 464



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88PSU PsychologyDesign and implementation of automated TA assignment systemRothrock, LingIE 480W









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89PSU QuantDev/StudioLab3-D Printing of Acoustic BowlsMenold, JessME 440W.7





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90PSU RERC on AAC 1Using Speech Recognition to Control the Home EnvironmentVerbanec, AlanCMPSC 483



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91PSU RERC on AAC 2The use of head-tracking and eye-tracking in challenging populations with the Intel RealSense RS300 Bilen, LennartCMPEN 482

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92PSU RERC on AAC 3ChatBot technology to support the acquisition of Active Listening SkillsVerbanec, AlanCMPSC 483



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93PSU START LabA compact thermocouple connector solution for gas turbine engine component testingLynch, StephenME 441W











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94PSU Sustainable Housing InitiativeHousing Taxonomy DatabaseEser, SemihEGEE 464



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95PTC Inc.The Internet of Things and Crisis Management Phase IIVerbanec, AlanCMPSC 483



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96Quaker Chemical CorporationMachining of Automotive Cast Aluminum AlloysImmel, MichaelIE 480W









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97Rain Reality LLCAugmented Reality Campus TourVerbanec, AlanCMPSC 483



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98SCA Americas 1The SCA Consumer Challenge Knecht, SeanEDSGN 460





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99SCA Americas 2The SCA Engineering Challenge Knecht, SeanEDSGN 460





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100Scientific Systems, Inc.Production Test Modernization/ImprovementPang, GuodongIE 480W









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101Shanghai ZJ Bio-Pharma Co.,Ltd.Automated Sample Preparation of Microbial Genome Nextera for High-throughput Sequencing - GLOBALRitter, SarahBME 450.1

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102Shell 1Shell Eco-Marathon - Team 1 (New Design)Neal, GaryME 440W.2


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103Shell 2Shell Eco-Marathon - Team 2 (Prototype)Neal, GaryME 440W.2


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104Shell 3Shell Eco-Marathon - Team 3 (Urban)Neal, GaryME 440W.2


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105Siemens Industry Inc. 1Design a Crude Oil Pump Station Functional Scale Model - Team 1Erdman, MichaelE SC 497


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106Siemens Industry Inc. 2Design a Crude Oil Pump Station Functional Scale Model - Team 2Knecht, SeanEDSGN 460


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107Sikorsky, A Lockheed Martin CompanyAdditive Manufacturing design project, using a Sikorsky Legacy partLynch, StephenME 441W










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108SMARTSEATSMART CAR BABY SEATWheeler, TimEE 403.1&2

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109The Boeing Company 1Mars Rover Project - Team 1 - GLOBAL with MelbourneWheeler, TimEE 403.1&2




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110The Boeing Company 2Mars Rover Project - Team 2 - GLOBAL with MelbourneErdman, MichaelE SC 497




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111The Bucktail Medical CenterEmergency room redesign in two stagesPurdum, CharlieIE 480W





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112The Shanghai General Fan Co.,Ltd.Optimal design of an axial fan - GLOBAL PROJECT with SJTUJefferies, RhettME 440W.3











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113Transverse Myelitis AssociationA device to open heavy doorsHayes, DanBME 450.2

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114TRS Technologies, Inc.Precision Chamfering of Piezoelectric Crystal Plates for Medical UltrasoundCannon, DaveIE 480W









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115Twigs Management LLCClub Claw Golf Club HeadcoverMenold, JessME 440W.7





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116Tyber Medical LLCProject UniteHayes, DanBME 450.2

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117Tyco (China) Investment Co. Ltd. 1Critical features study of new standard Helmets for firemen - GLOBAL PROJECT with SJTUJefferies, RhettME 440W.3

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118Tyco (China) Investment Co. Ltd. 2Gas cylinder management system - GLOBAL PROJECT with SJTUVerbanec, AlanCMPSC 483



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119Tyco Retail SolutionsFootware Tag - GLOBAL PROJECT with SJTUJefferies, RhettME 440W.3



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120Tyco Security ProductsRaspberry Pi Camera - GLOBAL PROJECT with SJTUWheeler, TimEE 403.1&2



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121UPMC SusquehannaEmployee Engagement and SatisfactionRothrock, LingIE 480W









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122Volvo CE North America, LLCUltrasonic Drum and Screed for Road ConstructionPerez Blanco, HoracioME 440W.4


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123Volvo Group, North AmericaAn EGR System Design for a Diesel Research Engine - GLOBAL PROJECT with Chalmers UniversityMoore, JasonME 440W.1





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124Volvo Trucks 1Research and Develop new fan blade shape, “divided fan blade” step2 - GLOBAL PROJECTMoore, JasonME 440W.1











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125Volvo Trucks 2tool for mounting/demounting of rotational design elements for use by robots and humans - GLOBALMoore, JasonME 440W.1







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126Volvo Trucks 3Modularization of Storage Spaces in Cabins with focus on cabinets for multi bra - GLOBAL PROJECTMoore, JasonME 440W.1





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127Well Master CorporationManufacturing Gap Analysis & Continuous Improvement - GLOBAL PROJECT WITH SJTUJefferies, RhettME 440W.3









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128X Material ProcessingMulti-Metal 3D Printing - Material RecoveryCannon, DaveIE 480W









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ArcelorMittal

Contact: Rachel Smithers

Address: 215 S. Front Street, Steelton, PA 17113

Project Title: Mechanical Cold Expansion of Drilled Bolt Holes - Team 1

Description: ArcelorMittal produces steel railroad rails for railroads, transit agencies, distributors, and crane operations at its facility in Steelton, Pennsylvania. Many of ArcelorMittal's transit customers purchase rail that is drilled (for joining with bolts); this drilling, with carbide cutting inserts, occurs at the time of cutting rails to finished length. Current state of the art requires that the drill holes be deburred on both sides of the hole to reduce the likelihood of introducing a stress riser that could lead to a material fracture. One transit agency (who relies on purchasing drilled rail) has introduced a new requirement into the specification; they want all bolt holes mechanically cold expanded, with a preference for a particular vendor. ArcelorMittal is trying to determine: 1. Will each drilled hole have to be expanded individually, or can multiple holes be expanded simultaneously for efficiency? 2. Is there more than one vendor that can satisfy the cold expansion requirement? Is there one that is preferable based on quality, efficiency, cost, ease of use, or other criteria? 3. What hazards are introduced into the manufacturing process by implementing mechanical cold expansion? 4. Is there a good way to install this technology on an existing line, or will we need to take the processing off-line? 5. What will it cost to purchase and install the equipment? What will be the ongoing cost to operate it (i.e. cost per unit after start-up, including both labor and consumables)?

Requested Dept.: ESM, Industrial, Mechanical

Requirements: none


Armstrong World Industries 1

Contact: William Frantz

Address: 2500 Columbia Ave, Lancaster, PA 17604

Project Title: Ceiling Tile Perimeter Mapping and Cutting System - Team 1

Description: OPPORTUNITY: Drop ceiling or suspended ceilings consist of a “tee-bar” grid system and square or rectangular ceiling tiles. When the grid is installed in real rooms, it is common for the grid openings along the perimeter of the room to be of “irregular size”. Each opening must be individually measured and ceiling tiles must be cut by hand to fit these openings. This process is one of the more time consuming steps in professional ceiling installation and requires some degree of skill. This process is also sometimes a barrier to a “Do-It-Your-Selfer” wanting to install their own ceiling. We want to improve this process. IDEA: We have an idea for a combined measurement and cutting system to make it easier and faster to cut “perimeter ceiling tiles”. We envision a “measurement tool” which could be used to accurately measure the size and shape of a grid opening. Perhaps this can be done with photogrammetry, ultrasonic range sensors, laser range finders, or some combination. We envision these data being communicated to an XY cutting table which would do the precise and unique cutting for that tile. The user would place an un-cut tile on the table. The table would use the “as-built” dimensional measurements to rapidly rout the tile. CAPSTONE WORK PACKAGE: Investigate options for measuring the openings. Investigate options for small 24 x 24 [in] CNC controlled table routers. Acquire or design/build a measurement system. Acquire or design/build a table cutting. Develop the software to convert as-build dimensional data to a G-code cutting file. Show working proof of concept. Perhaps one team might focus on the "measurement" aspect of the project and a second team might focus on the "cutting" part of the project.

Requested Dept.: CompSci, CSE, Electrical, Mechanical

Requirements: Confidential, Intellectual

Ceiling Tile Perimeter Mapping and Cutting System - Team 1


Armstrong World Industries 2

Contact: William Frantz

Address: 2500 Columbia Ave, Lancaster, PA 17604

Project Title: Ceiling Tile Perimeter Mapping and Cutting System - Team 2

Description: OPPORTUNITY: Drop ceiling or suspended ceilings consist of a “tee-bar” grid system and square or rectangular ceiling tiles. When the grid is installed in real rooms, it is common for the grid openings along the perimeter of the room to be of “irregular size”. Each opening must be individually measured and ceiling tiles must be cut by hand to fit these openings. This process is one of the more time consuming steps in professional ceiling installation and requires some degree of skill. This process is also sometimes a barrier to a “Do-It-Your-Selfer” wanting to install their own ceiling. We want to improve this process. IDEA: We have an idea for a combined measurement and cutting system to make it easier and faster to cut “perimeter ceiling tiles”. We envision a “measurement tool” which could be used to accurately measure the size and shape of a grid opening. Perhaps this can be done with photogrammetry, ultrasonic range sensors, laser range finders, or some combination. We envision these data being communicated to an XY cutting table which would do the precise and unique cutting for that tile. The user would place an un-cut tile on the table. The table would use the “as-built” dimensional measurements to rapidly rout the tile. CAPSTONE WORK PACKAGE: Investigate options for measuring the openings. Investigate options for small 24 x 24 [in] CNC controlled table routers. Acquire or design/build a measurement system. Acquire or design/build a table cutting. Develop the software to convert as-build dimensional data to a G-code cutting file. Show working proof of concept. Perhaps one team might focus on the "measurement" aspect of the project and a second team might focus on the "cutting" part of the project.

Requested Dept.: CompSci, CSE, Electrical, Mechanical

Requirements: Confidential, Intellectual

Ceiling Tile Perimeter Mapping and Cutting System - Team 2


AudioGo

Contact: Nick Smarto

Address: 268 S. Euclid Avenue, Pittsburgh, PA 15206

Project Title: Miniaturized wearable audio recorder

Description: AudioGo is a new Pittsburgh-based startup, developing wearable audio recorders for use in journalism, podcasting, and prosumer video production applications. We are creating a miniature field recorder to capture broadcast-quality audio with selectable pickup patterns, recording direct to microSD, and a bluetooth interface with companion mobile application. Student deliverables include: 1) Basic audio engineering, including contributions to microphone sourcing and beam-forming approaches. 2) PCB design including microcontroller programming, power consumption estimations, simple integrated digital signal processing (compression and limiting), interfacing (microSD card, app via bluetooth), and battery charging circuity. 3) Interface design, including app skeleton that interfaces with device and provides configuration and audio file access, in addition to hardware screen/button user interface. 4) Collaboration with sponsor on mechanical design, with focus on minimal size, so that PCB, screen, batteries and other components can fit within the desired space.

Requested Dept.: CSE, EDG, Electrical

Requirements: Confidential, Intellectual

Miniaturized wearable audio recorder


B. Braun Medical

Contact: Joel Bartholomew

Address: 901 Marcon Boulevard, Allentown , PA 18109

Project Title: 3D HYBRID METAL ADDITIVE MANUFACTURING for MOLD CAVITIES

Description: OPPORTUNITY To explore the ability to use Hybrid Metal Additive Manufacturing for injection mold cavities in place of traditional machining. PROJECT B. Braun Medical manufactures disposable devices. These devices are primarily manufactured from injection molded plastic parts. Injection molding and mold design are core competencies of the B. Braun Allentown facility. This project will focus on answering questions related to 3D Hybrid Metal Additive Manufacturing and its impact on manufacturing a mold cavity. QUESTIONS: • What accuracy can be achieved? • What surface finish can be achieved? • Can the printed cavities be polished? • What size limitations exist with the various equipment? • What types of steels can be printed? Tool steels? Stainless steels? • What is the hardness of the various printed steels? Can it be heat treated after printing? • Can the printed material be plated? Chrome, Nickel, other? • Are there stresses in the cavity? Similar to a machined cavity? CONCERNS: • Part release from the cavity? • Cavity alignment. • Proper fit into mold base. • Water channels printed in the cavity. DELIVERABLES: • A report on 3D Hybrid Metal Additive Manufacturing capabilities addressing the questions above. • Print one set of prototype mold cavities. • Dimensional and surface finish analysis of the cavity. • Send cavities to B. Braun for molding study. • Analysis of the parts from the mold cavities. • Print a second set of cavities with lessons learned. • Send cavities to B. Braun for molding study. • Analysis of the parts from the mold cavities. • Final report.

Requested Dept.: Bio, Industrial, MatSci, Mechanical

Requirements: Confidential, Intellectual


Bechtel Plant Machinery Inc

Contact: Matt Zamborsky and Jen Carvajal

Address: 135 Jamison Lane , Monroeville, PA 15146

Project Title: Personal Electronic Device Climate Controlled Container

Description: The project is to design and build a personal electronic device climate controlled container that maintains a climate for electronic devices to prevent overheating and excessive cooling. The climate controlled container can be used with a variety of electronic devices, and will be verified through analysis and testing. The project will provide exposure to electro-mechanical design and analysis, hands-on prototyping, and monitoring and control systems. The end deliverables will be a prototype that functions in accordance with the functional requirements document, as well as design documentation as required by the University. The project is intended for an evenly mixed team of electrical and mechanical engineers.

Requested Dept.: CSE, ESM, Electrical, Mechanical

Requirements: none


Bechtel Power Corporation

Contact: Stephen Routh

Address: 12011 Sunset Hills Road, Reston, VA 20190

Project Title: Heat Exchanging System for Fusion Power Reactor

Description: Bechtel is one of world’s oldest and largest Engineering, Procurement, and Construction companies. In addition to being the contractor of choice for a wide variety of power generation facilities for more than 60 years, Bechtel has led the emerging nuclear technology markets. Examples include the design and construction of the first U.S. reactor, EBR-1 (Experimental Breeder Reactor), the world’s first commercial nuclear power plant, Dresden, the world’s first HTGR (High Temperature Gas-Cooled Reactor), Peach Bottom, Canada’s first nuclear plant, NPO, and the first U.S. nuclear plant completed in 25 years, Watts Bar Unit 2. Recent examples are the management and operation of Lawrence Livermore National Laboratory’s National Ignition Facility and support of the design of Tri-Alpha’s Fusion Reactor design. The raison d’etre of an emerging technology is to build a better “mousetrap”. The proverbial mousetrap in clean/green nuclear power generation is the ultimate fusion reactor. Nuclear fusion is the nuclear reaction where two light atoms fuse with each other to create a heavier atom and release a large amount of energy. The most common fusion reaction is the combination of deuterium (D) and tritium (T) to create a helium nucleus (alpha particle). This reactor emits a 14.1 MeV neutron. The first and foremost advantage of fusion power generation is its byproduct or waste, which is not radioactive. Another advantage is that it is inherently safe without the concerns of core melt down or radioactive emission. Fusion power is, therefore, real clean and green energy. This proposed project is to design a heat exchanging system for a fusion reactor. The project team will perform the following tasks: 1)Understand the Tokamak and p-Boron 11 fusion reactor technologies based on publicly available information; 2)Select either one of Tokamak fusion reactor or p-Boron reactor technologies for study; 3)Design a conceptual heat exchanging system for the fusion reaction for power conversion. The 2017 Spring project will culminate in a 3D CAD drawing and 3D print out of the fusion heat exchanging system. The use of 3-D printing to illustrate the design would be the climax of this feat.

Requested Dept.: EDG, ESM, MatSci, Mechanical, Nuclear

Requirements: Intellectual


Bedford Reinforced Plastics Inc

Contact: Kevin Ickes

Address: 1 Corporate Dr, Suite 106, Bedford, PA 15522

Project Title: PROCESS IMPROVEMENT IN MIXING AREA

Description: For our process, on an average, we make 80 barrels of resin mixes per day. The resin mix involves mixing 5-6 ingredients which are liquids like resin, catalysts, mold release agents etc. and powders like clay and other proprietary additives and or fillers. The mixing process involves adding the liquids first and then adding the solids (powders) in predetermined amounts followed by mixing these thoroughly using industrial mixers. Out of these 80 barrels of resin mixes, about 90% of the mixes are of one particular type and the rest can be of different other mixes. Even though the mix composition and quality of our mixes are very accurate, we occasionally find some discrepancies due to human error which result in loss of material and machine time. Mixing a huge batch of resin mix in one shot may result in gelation of resin mix prior to the production depending on the weather conditions which makes the entire mix useless. Process Improvement Goal in the Mixing Area: We are looking for options on how we can alter or automate (using robots for example) the current process to increase the accuracy and consistency of our mix, make the process ergonomically efficient and environmentally friendly within a budget of $500,000.00 or less. The recommendations should include a report on: 1. Budgetary costs 2. Return on investment 3. Cost to benefit ratio.

Requested Dept.: CSE, Industrial

Requirements: Confidential, Intellectual


Bridge Gap Engineering, LLC

Contact: Peter Paone and Jeffrey Kutz

Address: 3299 Glase Road, Danielsville, PA 18038

Project Title: Positive Displacement Air Seal

Description: In many mechanical processes, the separation of materials according to size is required. On an industrial scale, many separation devices utilize airflow for the conveying of material through a separation device consisting of a rotating cage. The clearances around the rotating cage often allow for passage of materials through the device without the proper classification of the particles. This project will focus on developing a method to provide a positive seal in the system in order to avoid "short-circuiting" of material through the separator. The project is to develop the sealing mechanism through one such style of rotating separators, and to evaluate the amount and pressure of sealing air required, as well as the improvement in performance of the separator in classifying the material. The deliverable will be a report outlining: 1) The solution required to provide a positive seal to the rotating cage while ensuring the separator continues to function as intended. 2) The pressure and volume flow of air required to ensure that the seal is effective 3) An analysis of the change in separation efficiency of the machine, and the corresponding improvement in energy consumption of the system.

Requested Dept.: Energy, Mechanical

Requirements: none


Bridgestone Americas Tire Operations

Contact: John Lightner

Address: 10 East Firestone blvd, Akron, OH 44317

Project Title: Tire mounting support for Semi-Anechoic Chamber load frame

Description: The objective is to develop a system to support and position a tire/wheel assembly while it is being bolted to a load frame. The goal of this system is to add safety for the operator by eliminating lifting of the tire. The load frame has a bolt pattern similar to that of an automobile. One challenge is that the equipment based in the room must be minimized to avoid creating noise reflecting boundaries which would affect sound test measurements. There is a 48 inch door available to move equipment in and out of the room. There are also limitations on floor space around the load fixture due to microphones for measurement. The design load capacity is 200 pounds with a 50% overload capability (maximum 300 pounds). The tire/wheel assemblies range in size from 22 to 48 inches in diameter and 6 to 16 inches wide. The support system must allow for controlled vertical movement and rotation of the tire/wheel assembly to align with the bolt pattern on the load frame. A major consideration is operator ease of use. The solution may be floor operated or ceiling based.

Requested Dept.: Mechanical

Requirements: Confidential, Intellectual


Capital One

Contact: Luke Uliana

Address: 8020 Towers Crescent Dr, Vienna, VA 22182

Project Title: Transferring Money via Amazon Echo

Description: Capital One remains focused on implementing new technology that we can leverage within the financial service industry. We continue to seek opportunities where we can expand among our technology, as well as working with new and emerging products. As part of one of these products, Capital One has been playing around with the Amazon Echo. The Amazon Echo is a hands-free speaker with voice control. It connects to the Alexa Voice Service to provide news, music, weather, and more services people may use daily. The Capital One Capstone Project is to utilize the Amazon Echo with Alexa for bank transactions, particularly transferring money from one Capital One bank account to another. We can imagine these transactions to be like Venmo, but with voice activation on the Amazon Echo. This project is a continuation from last semester’s work. The team from last semester has already put in the functionality to transfer money from one bank account to another, as well as other basic functionalities that we are looking to expand on. We have lots of ideas to expand on, for example, allowing multiple bank accounts for one user, security/authentication, requesting a payment from a friend, etc. We are also keeping the ideas open to the team. For this project, students will work with testing out different sample skills that the Lambda Amazon service provides, and creating skills themselves. The languages that Amazon Web Services (AWS) Lambda support are Java, Python, and JavaScript/Node.js. The current project is built in Node.js, but if the team feels either of the other two languages will be better, then we will not limit it to only Node.js. On top of this, we will be leveraging different API’s to retrieve and send data. We will use Version Control with GitHub and manage the project with the Agile Framework. We will utilize the first meetings to help the team setup their environments, discuss the project and team goals, and include design thinking as needed.

Requested Dept.: CompSci, CSE

Requirements: none


Central PA SCI Support Group

Contact: Everett Hills, MD

Address: 1135 Old West Chocolate Avenue, Ste 101, Hummelstown, PA 17036

Project Title: Safe Snowboard Binding for Triple Amputee

Description: Overview: The purpose of this project is to create safe snowboard bindings that allow a man with bilateral above knee amputations and right above elbow amputation to safely and easily slip into and out of these bindings while wearing his "stubbies" - short prosthetic legs without knee joints. He must be able to secure and release the bindings with one hand. This individual is in the process of receiving a snowboard designed to his dimensions for height and weight. The team would be tasked with designing the best attachable bindings to this snowboard. The attachment and detachment must be accomplished using one hand. The team will be provided with the snowboard and overboard (with holes where the bindings will be attached.) Deliverables: One working snowboard that can be used by a man with three limb amputations to be delivered in time for the spring showcase. (A picture of the snowboard will be sent separately as user will not receive it until late December.)

Requested Dept.: Bio, EDG, Mechanical

Requirements: none


Chartlytics

Contact: David Stevens

Address: 200 Innovation Blvd; Ste 236, State College, PA 16801

Project Title: Wearable behavior counting device

Description: Wearable behavior counting / recording device Wearable device for counting and recording behavior in special education or autism center situations. When dealing with kids/adults with severe to moderate autism diagnosis, it is most time very difficult to count behavior. Teachers and therapists count behavior in order to understand the effects of their interventions on that behavior to produce accelerated outcomes. Here’s a video of multiple behaviors that need to be simultaneously counted and recorded. https://drive.google.com/open?id=0B27IJXJsvAJFOWdyWUhKdnFxVkE It is very hectic and chaotic sometimes and collecting good counts of different behaviors during instruction is very difficult. Needs • Comfortable to wear all day • Attaches with velcro and some stretchy breathable material • Battery lasts all day (or more) • Ability to configure buttons in an iOS / Android App to specify button function and relation to kids programs. • For example., some buttons can start independent timers, some buttons increment a count, other buttons could perform a split-lap function. • Buttons need to be identifiable through touch. Users may not be able to look at their “behavior gauntlet” as they are dealing with a violent student. • Buttons should provide some form of haptic feedback so users know they pressed the right one. • The app could provide audio feedback to the user through a bluetooth connected in ear headphone (ear bud). Each button could provide a different audio signal. Or text-to-voice information could be read back. • We could prototype it with 3D printing • And use C.H.I.P mini computer or raspberry pi, or arduino • The app will connect to a RESTful API powered by http://chartlytics.com/ Skills Needed Computer science Electrical Engineer Mechanical Engineer Bio-medical Engineer (?) 3d Printing Design Linux/Web/Javascript/Python

Requested Dept.: Bio, CompSci, CSE, Electrical, Mechanical

Requirements: Intellectual

Wearable behavior counting device


CIU#10 and Easter Seals

Contact: Jorene Proper

Address: 383 Rolling Ridge Dr., State College, PA 16801

Project Title: Easter Seals Sensory Room

Description: Sensory room The sensory room at Easter Seals provides unique sensory integration experiences for children of all ages and abilities. Designed with state of the art audio, music and lighting technologies, it provides valuable opportunities for sensory awareness, purposeful movement, self-expression, and recreation. Combining the audio system, the lighting effects, and the vibrating mats with the children's interactive switches allows them to see, feel, and hear the lighting, sound, and music. Unfortunately, because of the complexity of operations, the potential of this room is underutilized. The teachers and therapy staff have ideas for activities. We have a comprehensive operator's manual and user guide. What we need is the assistance of a team of engineering wizards to package the technology around the ideas and make it easily accessible. This project requires: -collaboration with educational and therapy staff about ideas and activities -trouble shooting problems with the room (like the fluorescent lighting) and creating or locating solutions -creating packages of special effects around themes and activities -developing a user friendly access to the theme packages and activities Please note: this project is presented by a nonprofit organization for consideration of grant funding. Possible costs may include: – Consultation fees, if needed by the team. – Purchase of accessories or equipment as recommended by the team – Basic repairs or maintenance or modifications recommended by the team

Requested Dept.: CompSci, CSE, EDG

Requirements: none

Easter Seals Sensory Room


CO Film Society

Contact: Sherry Fike

Address: 2338 Broadway, Boulder, CO 80304

Project Title: Boulder International Film Festival – Streamlining Operations Behind the Scenes

Description: The Boulder International Film Festival (BIFF), “is one of the coolest festivals in the world” writes Entertainment Magazine. What makes it “cool” and how does a small town show 50+ films across 6 venues, integrating talk-backs, film maker panels, youth programs and a robust music showcase? How does the non-profit and predominantly volunteer organization make BIFF a success for the 25,000 viewers each year? BIFF has been in existence for 12 years, and during that time it has gone from a completely paper-driven environment to a website, mobile app, online ticketing and intricate database of volunteers and shift assignments. But amidst the progress, festival preparations are manually intensive, rely on face-to-face communication and undocumented experience, and struggle with interdependencies which drive a critical integrated timeline of activities needed before the festival begins. Currently the BIFF Executive Director has used Microsoft Excel, Project and Adobe Illustrator to begin documenting BIFF planning activities and dependencies, and developing drafts of a master timeline and a guiding map for the BIFF leadership team. The purpose of this Capstone Project is to streamline this planning process and develop tool-driven products (current tools are only one option) so that the entire process is more accurate and efficient, less people dependent and can be reused year after year. Note that the project runs simultaneously with the preparations for BIFF 2017, which is scheduled for March 2-5, 2017. This will allow the students to fully understand what is needed to plan the festival, with the expectation that Capstone Project results will not be used until the following year. In addition, the goal is to have the students visit the CO Biff Office for a Project kickoff, and come to Boulder to help directly with the festival for a complete hands-on learning experience. A final visit after the Festival to present and deliver the products would be preferred if funds permit.

Requested Dept.: Industrial

Requirements: Intellectual

Boulder International Film Festival – Streamlining Operations Behind the Scenes


DiamondBack Truck Covers

Contact: Patrick Hanlon

Address: 200 Shady Lane Suite 130, Philipsburg, PA 16866

Project Title: Improving ergonomics in material handling

Description: Currently in our process we cut, bend, weld, and assemble 25-55 pound panels and move them manually from station to station and also move them within the station while working on them. Long term employees are starting to see some stress on shoulders, backs, and other joints from this repetitive, heavy, and awkward lifting. The panels are 4 feet by 6 feet in size and this presents an issue with ergonomics along with the weight of the panels. Some goals of a project would be a method to reduce the lifting strain and provide an assist/new method in the lifting and moving of the panels. A counter measure to this goal would be cost, and also the time or labor that it adds to the process. While some additional time is okay for the safety of the worker, the overall time addition should be a strong counter measure in the solution. If a time reduction is found due to the reduction in fatigue throughout the day that would be an additional benefit of the project but not the primary goal. Safety and enabling a wider range of people the ability to do the job is the goal

Requested Dept.: Industrial, Mechanical

Requirements: none


Discovery Space 1

Contact: Michele Crowl

Address: 112 W Foster Ave, State College, PA 16801

Project Title: Augmented Reality Sandbox

Description: Discovery Space is a hands-on children's science museum located in downtown State College. We are seeking a sandbox that utilizes augmented reality technology to allow users to manipulate topography. The exhibit will allow children to dig deep into the sand and see blue projected onto the sand, looking like water. As the sand is built up higher and higher, it turns into a mountain and eventually a volcano that will erupt. Children can manipulate the sand to change the flow of lava down the side of the volcano and more.

Requested Dept.: CompSci, CSE, ESM, MatSci, Mechanical

Requirements: none

Augmented Reality Sandbox


Discovery Space 2

Contact: Michelle Crowl

Address: 112 West Foster Avenue #1, State College, PA 16802

Project Title: Value Engineering at Discovery Space

Description: Discovery Space is a hands-on science museum for kids located in downtown State College, PA. Memberships with Discovery Space have more than doubled over the past five years, and space utilization has been maximized to the best extent possible. As Discovery Space has grown, the organization has evolved in response, and the roles and responsibilities of the Board, the staff, the committees. The volunteers have adapted as best as they can, but there is certainly room for improvement as Discovery Space evaluates opportunities for growth. Consequently, Discovery Space seeks help: (1) identifying, clarifying, and clearly scoping the roles and responsibilities of the Board, the staff, the committees, and the volunteers within the current organizational state of Discovery Space; (2) evaluating the staff capacity and resource levels in Discovery Space for both the current organizational state and possible future organizational states that are being considered; and (3) performing suitable value engineering analyses to quantify and evaluate the effectiveness and efficiency of the current and future Discovery Space organizational state. Deliverables include: (1) documentation and analysis of interviews and surveys conducted with the Board, the staff, the committees, and the volunteers at Discovery Space; (2) documentation of current and proposed roles and responsibilities for the Board, the staff, the committees, and the volunteers at Discovery Space; and (3) recommendations for streamlining operations and organizational structure at Discovery Space. Finally, a “stretch goal” for the team is to develop a simulation model based on their work and analyses to help Discovery Space evaluate future staffing needs, programming opportunities, and "what if" scenarios with respect to current and future resource and budgetary allocations.

Requested Dept.: Industrial

Requirements: none

Value Engineering at Discovery Space


Dresser-Rand, A Siemens Business 1

Contact: Jim Sorokes and Jenny Quan

Address: 500 Paul Clark Drive, Olean, NY 14760

Project Title: Centrifugal Impeller Axial Movement Study - GLOBAL PROJECT WITH SJTU

Description: See attachment

Requested Dept.: MatSci, Mechanical

Requirements: Confidential, Intellectual

Centrifugal Impeller Axial Movement Study - GLOBAL PROJECT WITH SJTU


Dresser-Rand, A Siemens Business 2

Contact: Jim Sorokes and Chris Guerra

Address: 500 Paul Clark Drive, Olean, NY 14760

Project Title: Printed Parts for Test Rig

Description: See attached...

Requested Dept.: Industrial, MatSci, Mechanical

Requirements: Confidential, Intellectual

Printed Parts for Test Rig


Dresser-Rand, A Siemens Business 3

Contact: Jim Sorokes and Soumitr Dey

Address: 500 Paul Clark Drive, Olean, NY 14760

Project Title: Rotatable Return Channel Vanes

Description: See attached...

Requested Dept.: Industrial, Mechanical

Requirements: Confidential, Intellectual

Rotatable Return Channel Vanes


Dresser-Rand, A Siemens Business 4

Contact: Jim Sorokes and Nick Burkhardt

Address: 500 Paul Clark Drive, Olean, NY 14760

Project Title: Non-Metallic Impeller Eye Labyrinth Seals

Description: See attached...

Requested Dept.: MatSci, Mechanical

Requirements: Confidential, Intellectual

Non-Metallic Impeller Eye Labyrinth Seals


Dresser-Rand, A Siemens Business 5

Contact: Jim Sorokes and Dave Peer

Address: 500 Paul Clark Drive, Olean, NY 14760

Project Title: High Pressure Case Seal

Description: See attached...

Requested Dept.: MatSci, Mechanical

Requirements: Confidential, Intellectual

High Pressure Case Seal


Dresser-Rand, A Siemens Business 6a

Contact: Jim Sorokes and Bill Maier

Address: 500 Paul Clark Drive, Olean, NY 14760

Project Title: OWC Turbine Mounting- Team 1

Description: See attached...

Requested Dept.: Energy, Mechanical

Requirements: Confidential, Intellectual

OWC Turbine Mounting- Team 1


Dresser-Rand, A Siemens Business 6b

Contact: Jim Sorokes and Bill Maier

Address: 500 Paul Clark Drive, Olean, NY 14760

Project Title: OWC Turbine Mounting - Team 2

Description: See attached...

Requested Dept.: Energy, Mechanical

Requirements: Confidential, Intellectual

OWC Turbine Mounting - Team 2


FedEx Services

Contact: James Connolly

Address: 1000 FedEx Drive, Coraopolis, Pa 15116

Project Title: Prototype next-generation sort application

Description: The objective is to create a prototype next-generation sortation application capable of determining the next load point for a package while traversing various FedEx networks. Network topology and transportation lane definitions will determine which destinations are accessible for any given facility. Using delivery destination latitude/longitude supplied by existing address cleansing software, compute the most efficient next load point for a package based on supported destinations for any given sort as well as the sort location latitude/longitude. This can be accomplished using spherical trigonometry. Oracle PL/SQL functions have been written and tested as part of a preliminary POC. Limit volume to a downstream next load point facility by reducing available trailer volume/weight at a given divert point. Make a divert point unavailable when this maximum cube/weight is exceeded until reset by a new trailer, or other adjustment to mathematical weight factors at a dashboard as managed by operations staff members.

Requested Dept.: CompSci, CSE, Industrial

Requirements: Confidential, Intellectual


Flowserve Corp.

Contact: Todd Koehler

Address: 1480 Valley Center Pkwy., Bethlehem, PA 18018

Project Title: Waste Heat Energy Recovery

Description: Flowserve is a world leading pump manufacturer that is continuously seeking new ways to improve the products that are provided to our customers and remain competitive in a very aggressive market. Most recently, the Flowserve Corporate R&D team has identified an opportunity in using thermoelectric generators (TEG) for waste heat energy recovery. High energy pumps, like those found in power plants, produce a tremendous amount of heat from the hot product they are pumping. Instead of being rejected to the surrounding environment, this “free” source of energy can be harvested to power numerous auxiliary equipment such as external fans, electric motors, other pumps, etc. Flowserve is interested in pursuing the design, construction, and testing of a TEG for waste heat energy recovery. The ideal TEG would be flexible or modular to enable the same device to be used on pumps of various sizes and shapes. The student team will focus on answering the following questions: o What current technology is capable of converting heat energy into electrical energy? o Maximum ambient temperature allowed? o Minimum heat source temperature required? o Will cooling of the device be necessary? If so, how will it be done? (heat sinks, cooling water, etc.) o How important is the contact surface between the TEG and hot pump surface? o Does the voltage need to be regulated, conditioned, or boosted? Throughout this project students will need to exercise their engineering judgment and intuition as they investigate this technology. The students will present their results, conclusions, and a working prototype to Flowserve. Project deliverables: o Working prototype demonstrating system operation. o A report outlining the design, construction, and experimental results of a thermoelectric waste heat energy recovery system which also answers the questions above o Engineering analysis justifying the system design

Requested Dept.: Energy, Electrical, Mechanical

Requirements: Confidential, Intellectual


Ford Motor Company 1

Contact: Frank Maslar

Address: 29500 Plymouth Rd, Livonia, MI 48150

Project Title: Ford Robot Vision Integration

Description: Business Case: Collaborative robots are increasingly being used in manufacturing operations because they are relatively affordable and easy to use. These robots are force and power limited and can often be deployed next to workers without the need for traditional safety guarding. One shortcoming of these robots, as well as traditional robots, is they lack the ability to “see” their environment and automatically compensate for changes in part location. Vision systems have been integrated into robot controllers, but they are relatively unsophisticated with limited capabilities. Objective: The objective of this project is to integrate a Cognex In-Sight smart camera with the Universal Robot controller software. The vision software should be integrated into the robot controller to ensure using the vision system is as easy to use as the robot. The In-Sight smart camera should be mounted onto the robot arm in such a way that it has a clear view of objects that will be picked up. The camera mounting needs to be as light as possible due to the limited payload of the Universal UR10 robot. Deliverables: • Determine the optimum mounting position and method for the camera on the robot • Determine the optimum camera field of view and required optics • Integrate the Cognex Insight software into the Universal Robot controller software • Develop the necessary algorithms for eye-hand calibration for the integrated system, and implement an easy to use calibration routine • Mount a simple gripper on the robot and demonstrate the effectiveness of the vision integration by grasping parts in random positions

Requested Dept.: CompSci, CSE, EDG, ESM, Electrical, Mechanical

Requirements: Intellectual


Ford Motor Company 2

Contact: Brodie Schultz

Address: 20901 Oakwood Blvd., Dearborn, MI 48124

Project Title: Evaluation and Optimization of a Press Die Pad Balancer Design

Description: Business Case: Pad balancers are used in secondary forming applications such as direct or cam flanging. At times the pad balancer does not function as intended and fractures. The impact force due to the velocity of the pad is occasionally high enough to plastically deform the panel leaving undesirable marks on the class "A" surface. Objective: Use velocity curves and tooling geometry provided to determine a situation (one for steel, one for aluminum) where the yield strength of the material being worked on is not exceeded by the impact force generated by the pad at point of contact. Take the current designs provided by Ford to conduct an analysis on functionality, determine the failure point(s), and provide potential improvements to the design. Deliverables: 1. Set up a FEA model based on the geometry provided to set a baseline analysis for determining current design and production issues. 2. Develop and validate “a solution” which minimizes the contact and impact force on the panel (material) being worked on and addresses all issues found in the analysis. The first solution should utilize shims to address issues. The remaining solutions should be developed by the students. All solutions will require an analysis for verification. 3. Determine the fracture limit for the pad balancer as more shims are added to the design. Conduct the same analysis for any designs suggested by the students. 4. Provide a document outlining the optimal design criteria for the pad balancer, and suggest any new design concepts based on the conducted analysis that Ford should explore for prototyping (evidence showing the new design concept will work and/or be an improvement over current design must be provided).

Requested Dept.: Mechanical

Requirements: none

Evaluation and Optimization of a Press Die Pad Balancer Design


Ford Motor Company 3

Contact: Heather Bronczyk

Address: 20901 Oakwood Blvd, Dearborn, MI 48121

Project Title: Optimized Rear Folding Vehicle Seat

Description: Current rear automotive seat designs often make trade-offs during the design process to some aspects of the seat in order to optimize other areas. The areas this project will focus on include occupant comfort and vehicle storage space (measured when the seat is folded). The goal for this project is to optimize the design of a rear seat by delivering a prototype that will fold with minimal thickness and still provide comfort for the occupant when in the upright position. (This could include the use of new/different materials, mechanical or pneumatic features, etc.) Deliverables: • Develop a method to measure the fold flat angle of the seat and the comfort of the seat • Characterize/measure the current seat design using the established method • Build an automotive seat prototype property starting with an existing automotive seat to demonstrate a system that will deliver a win-win strategy for fold flat angle and seat comfort • Re-characterize the seat to show with data that the prototype better delivers both attributes

Requested Dept.: ESM, Mechanical

Requirements: none


Ford Motor Company 4

Contact: Heather Bronczyk

Address: 20901 Oakwood Blvd, Dearborn, MI 48121

Project Title: Autonomous Vehicle Interior

Description: Autonomous vehicles offer a new take on vehicle design. There is still space to determine the optimal designs of interiors and seats to support this type of vehicle usage. How will occupants prefer to use this space? What will be unique or the same as vehicles today. The goal of this project is to generate an interior and/or seat design for a autonomous vehicle. This should include evidence to support the design elements selected, engineering feasibility and details explaining how it would be beneficial to autonomous vehicle owners/users. The project team should provide a model, virtual or physical (doesn't have to be full scale), of their design.

Requested Dept.: ESM, Mechanical

Requirements: none


GKN Aerospace Engine Systems

Contact: Rebecka Brommesson

Address: Flygmotorvägen , Trollhättan, SW 46138

Project Title: Research and develop additive manufactured bladed disks - GLOBAL PROJECT WITH CHALMERS

Description: Blisks (or bladed disks) are becoming more frequently used in the compressor module of turbofan aero engines. As compared to conventional disks with inserted compressor blades the blisk offers improved performance from an increase in design freedom and a decrease in weight. The baseline blisk concept is machining from a large block of forged material, a very expensive concept due to the time consuming machining and high material waste (low buy-to-fly ratio). The improved performance of the blisk over conventional disks therefore comes at an increased cost. One way to reduce material waste is to apply additive manufacturing (AM) methods where a part of the blade is built to a near net-shape. Since it is a rotating part the requirements on safety factors and thereby material properties and reliability is very high. Inertial forces and low cycle fatigue in combination with aero induced vibrations could quickly lead to failure in defect material. The aim of the proposed student project is to design a blisk for a civil aero engine application, using a combination of forged and additively manufactured material. During the project the students will gain insight in aspects of design and development of components in high performance industry. The project will consists of selecting a suitable AM method for the application, structural evaluation of a blisk component, manufacturing aspects and design. The project outcome should be a suitable AM blisk design as well as defined requirements on the selected AM process to achieve a competitive alternative. Tasks • Identify key performances indicators for blisks (bladed disks) • Analyze stresses due to operational conditions in current blisk • Literature survey on different AM materials/methods and chose appropriate candidates • Identify suitable areas/parts for 3D printing and analyze designs with respect to stresses and life length • Detailed design including interfaces between forged and 3D printed parts • 3D print plastic prototype Students: The project is in cooperation with Pennsylvania State University (Penn State). The project team will consist of three ME students from Chalmers and three ME students from Penn State

Requested Dept.: ESM, Mechanical

Requirements: Confidential

Research and develop additive manufactured bladed disks - GLOBAL PROJECT WITH CHALMERS


HC Starck

Contact: Helia Jalili

Address: HC Starck inc., Fabricated Products Group, Newton, MA 02461

Project Title: Wet Etching Trials on Multi-Layer Metallic Films for Display Technologies

Description: Overview. Electrodes for display technologies, ideally, should be processed in minimal steps. Industry standard etchants will require optimization to minimize processing steps. While this is a step forward process for a single metal thin film, multi-layer structures comprised of two or more metals are more challenging. In particular, the metals of interest are molybdenum and copper. Deliverables. HC Starck will deliver multiple double-layer films with varying thicknesses and/or compositions. The team is going to create a matrix of etchant composition, etching temperature and time to conducting etching efficiency experiments. The team will apply a mask for photoresist patterning. Team will produce etchants from given compositions and perform etching experiments. Features will be on the order of 100 micrometers, so etch success can be determined via optical microscopy. Promising etch results will require additional characterization using SEM and EDS. Further analysis of surface chemistry may be required using XPS and SIMS. Cleanroom training and access wil be required to carry out this project. A literature review will also be required to accompany experiments and data analysis.

Requested Dept.: MatSci

Requirements: Confidential, Intellectual


Horizon Signal Technologies

Contact: Jay Hunter

Address: 5 Corporate Blvd, Reading, PA 19608

Project Title: Solar Panel Tilt & Rotate - GLOBAL with The Belgium Campus (S. Africa)

Description: Horizon manufactures a portable traffic signal trailer that is equipped with flat lying solar panels We would like to have a way to rotate and tilt our solar panels on our trailers.

Requested Dept.: CSE, Energy, EDG, ESM, Electrical, Mechanical

Requirements: none

Solar Panel Tilt & Rotate - GLOBAL with The Belgium Campus (S. Africa)


Hyundai America Technical Center, Inc.

Contact: Byungho Lee

Address: 6800 Geddes Rd., Superior Township, MI 48198

Project Title: Design and Evaluation of BISG Supervisory Control Algorithm

Description: The Fuel Economy Development Team in Hyundai-Kia America Technical Center, Inc. (HATCI) is an engineering center that focuses on improving fuel economy of Hyundai/Kia vehicles for North American market. The team’s key roles and responsibilities are: • Establish targets for future fuel economy characteristics through analysis of current and future Hyundai and Kia vehicles as well as competitive vehicles. • Investigate new technologies, strategies, and methods to attain improved fuel economy in current and future Hyundai and Kia production vehicles while considering system costs, drivability, and performance impacts. • Analyze competitive data sets and assess future trends in fuel economy related technologies. • Lead activities for developing and integrating fuel economy related technologies (such as engine, torque converter & transmission, accessories, vehicle coastdown characteristics, as well as control logics and calibrations) to attain targeted vehicle fuel economy and to understand and document impacts/trade-offs to vehicle performance and drivability. • Understand and coordinate activities with Product Planning, Certification and Regulation teams on impact of proposed fuel economy technologies. The proposed project, titled “Design and Evaluation of BISG MHEV Supervisory Control Algorithm”, is particularly important to the organization since powertrain control development, integration, and optimization is one of the key areas that the team focuses for the future, especially in the area of vehicle electrification. Scope: - Obtain a Belt-driven Integrated Starter Generator (BISG) Mild Hybrid Electric Vehicle (MHEV) model in Autonomie, a full vehicle simulation tool developed by Argonne National Lab (ANL). - Re-design its supervisory control algorithm for BISG MHEV. - Improve fuel economy of the vehicle model on EPA's driving cycles (FTP75 & HWFET), compared to its default control algorithm. - Demonstrate the vehicle model can follow the US06 cycle trace. Deliverables: - A full report showing: (1) Control strategy of re-designed supervisory control algorithm (2) Improved fuel economy and analysis on how the re-designed algorithm achieved improved fuel economy over FTP & HWFET cycles (3) Vehicle simulation over US06 demonstrating there is no significance drop-off in its performance - A complete vehicle model (in MATLAB/Simulink/Stateflow) with a re-designed supervisory control algorithm -

Requested Dept.: CompSci, Energy, Electrical, Mechanical

Requirements: none


John Crane Inc.

Contact: Hao Feng; Jorge Pacheco

Address: 6400 Oakton St, Morton grove, IL 60053

Project Title: Automatic heating rig for Polymer element assembly process - GLOBAL PROJECT WITH SJTU

Description: John Crane is a leading provider of products and services to global energy services customers. Our solutions help ensure the reliability of mission-critical equipment in challenging operating environments. Today, John Crane is the largest subsidiary of Smiths Group plc. Our solutions — ranging from mechanical seals, filtration systems, and bearings to couplings — are backed by the largest global service network in the industry. We combine technical expertise and innovation, geographic reach, and superior quality standards with customer service to provide the reliability, efficiency, and constant uptime on which our customers depend. Today’s oil and gas producers are challenged with addressing the growing demand for energy in a more efficient and economical way. In the gas seal assembly workshop, the polymer element is mounted on the sleeve. The polymer ring is stretched to be assembled on the sleeve. After that, the polymer ring needs to be heated up to certain temperature in order to get it back to original shape and dimension. Currently, this assembly and heating process is all manual, to enhance the assembly quality and efficiency, an automatic heating mounting rig is desired. The rig should contain two parts. One is a flat plate bench rotating automatically around 0.1- 0.5 RPM. The other is a heating device which could move X and Y axis position freely and could control the heating Temperature automatically. Also it will be beneficial to have an alarm for the operation after the process is done. Furthermore, the assembly tool should be flexible to different size polymers.

Requested Dept.: Mechanical

Requirements: none

Automatic heating rig for Polymer element assembly process - GLOBAL PROJECT WITH SJTU


John Deere

Contact: Jonathan Dylhoff

Address: 700 Horizon South Parkway, grovetown, GA 30813

Project Title: Flexible Piping for Diesel Exhaust Systems 2

Description: Flexible Piping for Diesel Exhaust Systems - 2 Diesel Exhaust systems meeting Interim Tier 4 and Final Tier 4 EPA emission standards typically require complicated piping that might include sections of flexible pipe. These flexible sections both mitigate vibration and improve assembly tolerances for the exhaust pipe between various components. Qualification of the flexible pipe sections is important to maintain durability, quality and conformance to emissions standards. Currently the options for flexible piping are limited and single sourced due to complexity in design and ability to quickly qualify. It is desired to create a test stand that can mimic the tractor environment and loads in order to qualify new flexible pipe designs. Some test stand variables would include flowing hot gas, multi-direction vibration, measurement devices, and detection devices. Existing designs would be used as baselines and future designs could be measured against them. An existing test stand is available to utilize for development. A successful Spring 2017 project would take the test stand to the next level. It would add feedback for temperature in the bellows and position sensing for feedback during vibration. Additional success would include analysis of the existing bellows design, predict failure given FEA tools, and perform various tests to failure (varying vibration displacement, axial misalignment, and temperature). After performing the analysis and tests the team would propose a design change to meet the in-vehicle vibration and assembly tolerances (longer, shorter, etc).

Requested Dept.: Mechanical

Requirements: none

Flexible Piping for Diesel Exhaust Systems 2


LB&A Consulting Group, LLC

Contact: Tom Hartman

Address: 2875 Corte Morera, Carlsbad, CA 92009

Project Title: Making music with 3D printed drumsticks

Description: To many, a pair of drumsticks may seem like two simple pieces of wood, but to experienced drummers, drumsticks are finely crafted works of art. Top of the line drumsticks are carefully made to a specific drummer’s needs, and special types of wood are used to ensure the right response for each pair. Unfortunately, drummers can go through multiple sets of drumsticks in a single show, and the resources to make drumsticks are become more and more scarce. Tuning a pair of wooden drumsticks to match perfectly is also a challenge. In this project, we seek a multidisciplinary team of students to help us investigate the feasibility of 3D printing drumsticks. Starting with a standard 17.5" drumstick, the team should investigate different CAD designs, material options (e.g., PLA, ABS, Polycarbonate), 3D printing processes (e.g., material extrusion, material jetting, vat photopolymerization), and customization features that are possible through design, material, and process variations. The team will then produce multiple full-scale prototypes for testing and evaluation with the goal of having at least 3 alpha prototypes by the 1st of February and 3 beta prototypes by the 1st of March. Additional design enhancement and customizability will be developed and tested in the latter half of the semester before producing 3 final prototypes by the end of the semester.

Requested Dept.: CSE, EDG, Electrical, Industrial, MatSci, Mechanical

Requirements: Confidential, Intellectual

Making music with 3D printed drumsticks


Lockheed Martin

Contact: Mark Schaffer

Address: 1801 State Route17C , Owego, NY 13827

Project Title: RF ID Keyed Gate

Description: Lockheed Martin is creating “Innovation Garage” spaces across the company’s Rotary and Missions Systems business unit. These areas are set up as maker spaces and are provided to employees so that they can work on personal projects. Employees have access to various tools and materials such as Raspberry Pi’s and 3D Printers. The team will be responsible for designing and building an RF ID keyed gate for access to the Innovation Garage workspace. The development of this system will require the design and build of a latching/locking mechanism and RF ID interface with the ability to store access entries in a database. The system should also allow the ability to export the database. This should utilize open source devices such as a Raspberry Pi or Arduino. The team will be responsible for delivering either a physical gate with RF ID Keyed mechanism fixed to it or a system that could be easily mounted to a gate built in the future. It is also desired that the team design a similar system for the tool cabinet with an interface that logs what users have check out/in specific tools or materials.

Requested Dept.: CompSci, Electrical, Mechanical

Requirements: none


Lord Corporation

Contact: Conor M Marr

Address: 2455 Robison Road W., Erie, PA 16509

Project Title: Design of A Bumper - GLOBAL PROJECT with SJTU

Description: Bumpers are widely used products on many transportation vehicles to absorb shock or prevent damage. With the increase of performance and reliability requirements, design optimization is critical to develop a part successfully within short lead times. The goal of this project is to design a bumper which could provide a desired load-deflection performance within the given envelope, with a maximum principle strain in the elastomer of less than 60%. A number of computer aided design tools, such as 3D CAD, topology optimization, non-linear FEA etc. should be used. A. Dimensions Refer to existing system B. Under the following deflections, the bumper will be within 15% of the target load listed. Deflection. (mm) Design Target Load(N) 5 1,000 10 2,500 15 7,000 20 20,000 25 45,000 C. Project Deliverables a) Detailed design report clearly stating assumptions and design choices, projected costs, bill of materials, discussion of the design, and post processed FEA results. b) CAD models of the design c) Drawings of the final design d) Prototype of the design(3D print?)

Requested Dept.: ESM, Mechanical

Requirements: Confidential, Intellectual

Design of A Bumper - GLOBAL PROJECT with SJTU


Lycoming Engines

Contact: Zach Mihalov

Address: 652 Oliver Street, Williamsport, PA 17701

Project Title: Starter Ring Gear Support Design and Analysis

Description: Problem Statement: Lycoming Engines manufactures air-cooled piston engines for general aviation aircraft, ranging from 100 to 400 horsepower. Lycoming is seeking to improve the design of the starter ring gear support used on legacy engine models. The current ring gear support is a solid disk design; a new design is sought to reduce weight and improve producibility. The team will first create a detailed analysis of the current component design as a preliminary baseline for comparison. Based on the preliminary analysis, students will make design changes to reduce total component weight without sacrificing strength, reliability, or safety factor. To aide in the design process, students are expected to use a finite element analysis software package to provide a detailed stress contour. Primary deliverables will then include a detailed report and presentation to Lycoming of a new design option with analysis including component stress, cost, and manufacturability. A model of the improved design may be made for comparison. Requirements: - Understanding the function of a starter ring gear support - Analysis of current starter ring gear support - Research on available materials and their impact on component strength, weight, and cost - Analysis of the recommended starter ring gear support design - Detailed technical report; Model Provided Materials/Information: - Engine performance data (power output, speed, etc.) and ring gear requirements - Available drawings and CAD models of current starter ring gear designs

Requested Dept.: ESM, Mechanical

Requirements: Confidential, Intellectual

Starter Ring Gear Support Design and Analysis


Marathon Petroleum Company

Contact: Henry Matthews

Address: 539 South Main Street, Findlay, Oh 45840

Project Title: Above Ground Storage Tank Static Electricity and Lightning Mitigation - Phase 2

Description: This is phase 2 of a project that originated in the Spring 2016 Capstone Design Project session. Marathon Petroleum wishes to continue the evaluation of the impacts of static electricity and lightning on external floating roof storage tanks. The objective is to evaluate the effectiveness of several tank bonding methods that help divert potentially hazardous charge accumumations to ground. This project will involve using a tank model from the previous session. It will also involve fabricating a test apparatus to measure voltages and currents through bonding conductors used to drain accumulated charges from the tank surface. It is desired to develop a computer model that simulates the tank/model,evaluates the effectiveness of the bonding cables by measuring the voltages and currents present on the tank surfaces. The cables are to be tested in various configurations/displacements around the tank roof and the model will take into consideration the types of metals used for the tank construction - steel, stainless steel etc.

Requested Dept.: CSE, Energy, Electrical, MatSci, Mechanical

Requirements: none

Above Ground Storage Tank Static Electricity and Lightning Mitigation - Phase 2


Night Vision and Electronic Sensors Directorate (NVESD) 1

Contact: Rita Coghlan

Address: 10221 Burbeck Road, Fort Belvoir, VA 22060

Project Title: Feed Tray Cover Shock Simulator

Description: The objective of this project is to design and prototype a feed tray cover shock simulator that can replicate feed tray shock for the M249, M240B/L and M2 weapons. The simulator will need to fit and operate within a thermal chamber, to facilitate testing over temperature. Project Background: The Night Vision and Electronic Sensors Directorate (NVESD) researches, develops and prototypes products to support the Army’s needs. The prototypes can include weapon sights that are suitable for use on the M249, M240B, M240L, and the M2 weapons. Significant shock is introduced into the weapon side when the feed track is closed. For repeatable measurements, especially over temperature (as material properties change), a simulator device is needed to replace using an actual weapon. Project Requirements: The project requires a design that can mount the weapon sights (of a variety of masses, lengths, and properties), and replicate the physical characteristics of the weapon to produce a shock profile identical to the different weapon platforms. A working prototype of the design is required, and a full set of sensors attached to the unit to log data (temperature, pressure, accelerometers). Students will be required to measure feed tray closure shock on the actual weapons and comparison data from existing collections will be provided. Project Deliverables: Deliverables include: a. Detailed design report b. CAD drawings of the components c. CAD models of the assembly and components d. Description of installation and assembly instructions e. Operations manual f. Cost estimate g. Video of system in operating h. Test report of a provided weapon sight for test i. Stretch Goal: Video from the weapon sight while under test

Requested Dept.: CompSci, EDG, ESM, Electrical, Mechanical

Requirements: none

Feed Tray Cover Shock Simulator


Night Vision and Electronic Sensors Directorate (NVESD) 2

Contact: Rita Coghlan

Address: 10221 Burbeck Road, Fort Belvoir, VA 22060

Project Title: Tank Motion Simulator

Description: Project Objective: The objective of this project to design and prototype a Tank Motion Simulator for use with computer vision, and augmented reality systems. The simulator is intended to be made up of a series of pan and tilts (gimbals) attached to each other - one for the body, turret, and long range sensor. A computer application allowing for control of the simulator, along with a 3D representation of the simulated tank is expected. The simulator should allow for easy attachment to a vehicle (HMMWV) that replaces the body pan and tilt. Project Background: The Night Vision and Electronic Sensors Directorate (NVESD) researches, develops and prototypes products to support the Army’s needs. The prototypes can include sensors for use for driving, targeting, reconnaissance and surveillance. Emplacing sensors and providing proof of concept demonstrations can be a costly and time intensive task for integrating with large military armored vehicles. A development platform that simulates tank motion, include slew rates, and available pointing angles, and the spatial transformations necessary for computer vision is desired. This platform will be used to prototype computer vision and augmented reality capabilities in a laboratory, then transferred to a vehicle for outdoor testing. A 3D representation of the simulated tank, while the pan and tilts are running, will allow for visualization, and debugging of the system. It’s expected that the pan and tilts range of motion, will be larger than the simulated armor vehicle – it’s desired that this constraint will be visually represented. Project Requirements: The project requires a design that can mount the pan and tilts to each other – best representing the armored platform. Additionally, the turret and long range sensor pan and tilt will need to be easily transferred to a HUMWWV for outdoor testing. The correct interface control documents will need to be adhered to, and computer control of the pan and tilts implemented. The application showing the 3D representation of the armored platform will need to be written. The pan and tilt devices can be provided for the students use. A stretch goal, to integrate an imaging sensor, the appropriate sensors, and demonstrate an augmented reality user interface. Project Deliverables: Deliverables include: a. Detailed design report b. CAD drawings of the components c. CAD models of the assembly and components d. Description of installation and assembly instructions e. Operations manual f. Cost estimate g. Video of system in operation h. Software of the 3D simulated armored vehicle i. Software for the command/control of the simulator j. Integration of the necessary sensors (encoders, and/or inertial measurement units) k. Stretch Goal: Integration of an imaging sensor, with an augmented reality user interface

Requested Dept.: CompSci, EDG, ESM, Electrical, Mechanical

Requirements: none

Tank Motion Simulator


Penn Machine Company 1

Contact: Greg Holt

Address: 310 Innovation Drive, Blairsville, PA 15717

Project Title: Design of Mechanically Fastened Rail Road Wheels

Description: Design of a Mechanically Fastened Transit Railroad Wheel Overview The current state of the art for attaching a rail wheel to an axle is to utilize an interference fit and press the wheel over the axle. This method requires very tight tolerances for both the wheel and axle along with a specialized press. The measurement for a successful mounting requires monitoring the tonnage required to press the wheel onto the axle and meeting a prescribed minimum. Problem Statement Removing a rail wheel from a transit vehicle is not an easy task. It requires that the vehicle be removed from service, placed under a crane or lifting device to remove the truck. Then the axle assembly is removed from the truck. If the agency has an axle press they can press off the wheel. If they do not have a press, the axle assembly must be sent to a facility with the capability to remove the wheel. A wheel design that allows easy and quick removal without the need to remove and disassemble the truck will be a significant improvement to rail service operations. Project Goal The goal of this project is to design a wheel/axle interface that will allow mounting with fasteners, or a novel mechanical joint. The interface must be robust to handle the dynamic loading condition as well as meeting federal rail standards. Allow easy wheel change with non-specialized tools. Project Benefit The benefits of a mechanical fastened wheel include: • Elimination of the requirement to press. • No special press required to mount by the OEM or the transit agency • Reduction of the tight tolerances required for press fit (reduction of manufacturing cost) • Ability to change a wheel easily by the transit agency Project Deliverables • Detailed search of prior art to determine patent-ability and to ensure no infringements • Full solid model and manufacturing drawings • Material selection • Hardware Selection • Finite element analysis of the system • Manufacturing cost estimate • Final report Events at Penn Machine • Project Kick-Off Meeting • Patent-ability Review Meeting • Preliminary Design Review prior to FEA • Final Design Review and Presentation

Requested Dept.: Mechanical

Requirements: Confidential, Intellectual

Design of Mechanically Fastened Rail Road Wheels


Penn Machine Company 2

Contact: Greg Holt

Address: 310 Innovation Drive, Blairsville, PA 15717

Project Title: Design of Wheel Sensors to Monitor Railroad Wheel Health

Description: Design of Wheel Sensors to Monitor Railroad Wheel Health Overview Predictive maintenance and real-time alert to potential rail wheel damage or wear can increase passenger safety and reduce operation cost. Introducing wireless sensor technology into transit railroad wheels can provide data to measure trends in vibration and temperature thereby alerting operations of impending issues. Problem Statement Having real time data over a long term operation of a rail wheel can provide information on maintenance requirements and safety concerns. For example, if a wheel temperature or vibration profile is trending upward over time, it may be possible to set thresholds to indicate the onset failure event or a replacement requirement. Alternatively, if there is a sudden change in temperature or vibration, it can indicate a failure event. Instrumenting rail wheels has been done for testing and evaluation of new wheel designs. These setups were designed for short term tests and not lifetime data collection. Project Goal The goal of this project is to identify or design wireless sensors appropriate for installation into a rail wheel on a production basis with a life expectancy of seven to ten years. Sensors should be able to transmit data to an on-board collection devise. Considerations should be made to recommend methods for data transfer off-board either continuously, or at specified locations. Sensors shall be able to measure vibration and temperature. There are two additional challenges of this project that may be added. Provide a means to measure lateral measurement between the tire and the wheel center, and develop a method to identify a crack within the wheel assembly. Penn machine will provide full solid model of the wheel assembly and an actual wheel to modify with sensors. Although it will not be possible to collect actual data with this wheel installed on a rail vehicle, a simulation of the instrumented wheel is the goal. Project Deliverables • Detailed search of prior art to determine patentability and to ensure no infringements • Full solid model and manufacturing drawings of the proposed solution • Design of a simulation test stand • Hardware Selection • Manufacturing cost estimate • Final report Events at Penn Machine • Project Kick-Off Meeting • Patentability Review Meeting • Preliminary Design Review prior to FEA • Final Design Review and Presentation

Requested Dept.: EDG, Electrical, Mechanical

Requirements: Confidential, Intellectual

Design of Wheel Sensors to Monitor Railroad Wheel Health


Philips Ultrasound 1

Contact: Charles Cruikshank

Address: 1 Echo Drive, Reedsville, PA 17084

Project Title: Vertical Lift Module Inventory Optimizatioin

Description: Description: Philips Ultrasound has recently installed two Vertical Lift Module inventory storage systems. The system has not been optimized for material and package size. Inventory storage and retrieval flow has not been optimized. Project: The student team will: 1. Optimize the VLM system for material size / grouping 2. Optimize the VLM for Part Pick speed 3. Recommend vendor provided part packaging to optimize VLM loading / Picking 4. Provide an optimized head count model for the stock room 5. Optimize work flow for scrap replacement, work order fulfillment and VLM loading

Requested Dept.: Industrial

Requirements: Confidential


Philips Ultrasound 2

Contact: Charles Cruikshank

Address: 1 Echo Drive, Reedsville, PA 17084

Project Title: Factory Material Movement and Transaction Optimization

Description: Title: Factory Material Movement and Transaction Optimization Description: Philips Ultrasound is expanding manufacturing space for a portion the transducer assembly operations. The operations will be inside a Clean Room and will require efficient product flow and inventory management. The project will have 2 product lines (C5-1 and C9-2) in scope for optimization. Project: The student team will: 1. Map the current state of material flow and MRP transaction activity. 2. Provide an Optimized product flow plan for use in the expanded clean room 3. Provide a plan for Optimized MRP transactions in the clean room 4. Design Optimize storage locations and method for materials in the clean room 5. Key Metrics to improve / monitor will be; Transaction touch time, Material travel distance

Requested Dept.: Industrial

Requirements: Confidential


PSU Alumni Association

Contact: Jeff Kukitz

Address: Hintz Family Alumni Center, University Park, PA 16802

Project Title: PSAA Production Process Analysis

Description: The Penn State Alumni Association is interested in streamlining internal processes and creating efficiencies in order to maximize our ability to produce programs and content to engage with our diverse alumni base. We would like to examine the end-to-end process for Strategic Communications, which involves inbound requests from several business units, production, proofing, editing, approval of final drafts, and archiving of materials for future use. Specifically, we would like to propose a project where a team of IE students would be able to document existing process workflows and benchmark process output, and assist in the identification and selection of a software solution that will allow us to measure throughput and manage process improvements.

Requested Dept.: Industrial

Requirements: none


PSU BME 1

Contact: Peter Butler

Address: 101 Hammond Building, University Park, PA 16802

Project Title: Dev. of a simulated flow environment for nanoparticle delivery to atherogenic endothelium - GLOBAL

Description: GLOBAL PROJECT with SJTU Students will design, build, and test a novel chamber to simulate the types of blood flow that occurs near diseased blood vessels. The goal is to develop ways to deliver nanoparticles that could encapsulate drugs that could be used to treat the diseased tissue. Students will need to have a working knowledge of fluid dynamics theory and simulation, be interested in fabricating and building, and have a good working knowledge of vascular biology. BME, ME, CHE students are most likely to excel in this project. Overall project: Cardiovascular disease is the No. 1 cause of death in the United States and causes approximately 1 million deaths each year. Atherosclerosis, or the thickening and hardening of the arteries, is the usual cause of the disease. With the development of nanoparticle drug treatments, scientists and researchers hope to target atherosclerotic lesions to more effectively combat the disease. Computational models simulating the delivery of nanoparticles would help researchers and scientist to design nanoparticles that take advantage of the unique flow characteristics such as low shear, recirculating flow and regions of increased permeability commonly associated with the development of atherosclerosis. A backward facing step chamber is commonly used to study and simulate flow characteristic of atherosclerosis. The step creates a recirculating flow region similar to what is found in arterial bifurcations where there is a high risk of atherosclerosis development. This geometry is also easily creatable in a lab setting and can be modeled in 2D, which greatly reduces computational time. Using Comsol Multiphysics software, this flow chamber was modeled and its velocity and pressure profiles were computed using the Navier-Stokes equations assuming steady, incompressible flow. A particle tracing study was then performed utilizing the calculated flow velocities and pressures. In a time dependent study spanning 5 seconds, 15,500 nanoparticles with 50nm diameters were released at the inlet and the number of particles to reach the bottom wall after the step was counted. The simulation focused on how nanoparticles reached the vessel wall and mostly ignored the adhesion dynamics involved in nanoparticle uptake. The types of forces and flow characteristics to be applied to the nanoparticles were determined by systematically adding various forces to the simulation and examining its influence on the number of nanoparticles reaching the wall. Drag force, Brownian motion, interstitial flow, gravity, and particle-particle interactions were the main forces considered. It was found that the combination of drag force and Brownian motion, which combine to simulate diffusion, is required for any particles to reach the wall. With the addition of interstitial flow, which was modeled with 14, 100nm outlets along the bottom of the flow chamber, the number of particles reaching the wall jumped from 34 to 46. Gravity was found to have very little effect, contributing to only a 6% reduction of delivered nanoparticles. The modeling of particle-particle interactions was found to be very computationally expensive which restricted the number of particles in the simulation to be less than 100. At this low concentration it was found that none of the particles reached the wall. These results show that diffusion and interstitial flow have a significant role to play in pulling nanoparticles out of streamlines such that they reach the vessel wall. The next steps involve recreating this simulation in a lab setting to include this increased permeability seen in atherosclerosis. The experiment will be used to validate and improve upon the computational model. The simulation will allow researchers to investigate and better understand how nanoparticles are transported to atherosclerotic lesions under conditions specific to atherosclerotic development. Ultimately, the knowledge gained from these models should help direct the field of nanomedicine to make treatments of atherosclerosis more effective.

Requested Dept.: Bio, ESM, Mechanical

Requirements: none

Dev. of a simulated flow environment for nanoparticle delivery to atherogenic endothelium - GLOBAL


PSU BME 2

Contact: Siu Ling LEUNG

Address: 206 Hallowell Building , University Park, PA 16801

Project Title: Dev. of a cardiac fluid flow analysis system to study fluid dynamic in carotid artery stenosi-GLOBAL

Description: GLOBAL PROJECT WITH SJTU - Carotid artery disease happens when atherosclerosis develops on the inside of the vessels. This decreases blood flow to the brain and increases the risk of a stroke. Study the fluid dynamic within the carotid artery could help studying the cause of atherosclerosis and developing potential cure for the disease. The goal of this project is to develop a cardiac fluid flow analysis system that allow us to study the fluid dynamic within normal carotid artery or custom carotid disease models. One the hardware side, the system should allow steady and pulsatile inflow to the carotid artery with controllable flow rate. Fluid flow will be visualized by particle image velocimetry with customized program to output flow trajectory, velocity and shear stress in all locations. Undergraduate students will be the end user of this system. A portable, waterproof, easy to use and clean up system that can be taken to any classroom is required. This project we will need expertise in BME, ME, EE, CS and/or CE.

Requested Dept.: Bio, CompSci, CSE, ESM, Electrical, Mechanical

Requirements: none

Dev. of a cardiac fluid flow analysis system to study fluid dynamic in carotid artery stenosi-GLOBAL


PSU Children's Hospital

Contact: John Myers and Sean Knecht

Address: University Park and MS Hershey Med Ctr, Hershey, PA 17033

Project Title: Low-temperature plasma sterilization of medical equipment: the Sorin 3T Heater/Cooler

Description: Plasma is often referred to as the fourth state of matter, produced by providing significant energy to a fluid (gas or liquid), often through the application of a high voltage and the resulting electric field. Plasma makes up 99% of the observable universe, in particular stars and the intergalactic and interplanetary space, but are less apparent on Earth. Terrestrial examples of plasma that are readily observed include lightning, the Aurora Borealis and fluorescent light bulbs. Plasma comes in a wide range of temperatures and particle densities depending on the application. For instance, nuclear fusion plasmas are fairly low density, but with temperatures of 100 million degrees, and require ultra-high vacuum conditions to produce. This project focuses on a different regime of plasmas that is generated at atmospheric pressure and has temperatures only slightly higher than room temperature, making the engineering significantly simpler than fusion plasmas. This regime is referred to as low-temperature plasma (LTP). LTP can be generated by applying a high voltage potential (kV’s) across a capacitive electrode configuration. This means that there are two conductors, a “ground”, or zero-voltage electrode, and a “hot”, or high-voltage, electrode. The conductors are separated by a dielectric (non-conducting) material such as glass or plastic. A difference in voltage across some distance results in an electric field, as shown in Figure 1 (see below). Electric fields can accelerate charged particles; in this case electrons that are not bound to a nucleus (free electrons). Accelerated electrons will eventually collide with other atoms or molecules in the area. In the case of an electric field generated in the air, electrons will collide with nitrogen molecules or oxygen molecules. Depending on the kinetic energy (velocity) that the electrons have acquired from the electric field prior to collision, there are three primary outcomes of interest: 1) The electrons have sufficient energy to liberate another electron from the atom/molecule. This is called ionization and results in plasma generation. 2) The electrons have insufficient energy for ionization, but sufficient energy to overcome the bond dissociation energy of molecules. This is a dissociation collision and results in atomic species generated from molecules. 3) Electrons have enough energy to excite bound electrons in atoms and molecules to higher energy levels, but not to ionize, nor to dissociate. These are called excitation collisions. Of particular interest to this project are dissociation collisions and excitation collisions which produce radical, chemically-reactive atomic and molecular species, such as reactive oxygen species (ROS) like atomic oxygen, nitric oxide, ozone, hydroxide, hydrogen peroxide, etc, as shown in Figure 2 (see below). Reactive oxygen species that are exposed to living cells result in oxidative stress to the cells. Sufficient oxidative stress to any type of cell (human, bacterial, etc.) is uniformly fatal, though that limit of stress can be different from one cell type to another. This biocidal capability of LTP is the technology of interest for this project. The “dry” nature of the plasma is also of considerable interest by removing the necessity for the disposal of hazardous chemicals and solvents after disinfection. Moreover, the low gas temperatures and low driven currents reduces concerns regarding thermal or electrical damage from the system. The student team will design a low-temperature plasma delivery system that can disinfect the subject hospital equipment, a Sorin 3T Heater/Cooler machine that becomes contaminated with non-tuberculosis mycobacteria (NTM). NTM is a slow-growing bacteria that is not often dangerous for healthy individuals, but is a significant concern for immune-compromised patients, such as those that have just undergone invasive surgery. The student team will need to consider the various types of low-temperature plasma electrode geometries and materials that are found in the literature, as well as the various mediums in which the plasma can be generated (noble gases, air, liquids, etc.) and determine the best approach to plasma generation under the given circumstances. One such geometry is shown in Figure 3 (see below), a helium carrier gas plasma jet. The necessary electrical equipment for plasma generation is available through Dr. Sean Knecht. Due to legal considerations, the actual Sorin 3T Heater/Cooler machines of interest to the technical sponsor are not likely to be available for experimentation or prototyping. For this reason, an aspect of the project will be to recreate the parts of the machine that the bacteria contaminates. This includes the materials, geometry and various inlet/outlets of the system. This will provide a suitable prototype on which to evaluate plasma delivery systems. Work will be performed in parallel by Dr. Knecht to specifically evaluate the sterilizing effect of LTP on cultured NTM. An additional component of this project that may be pursued is the effect of prolonged (minutes to hours) exposure of LTP to the materials and electronics associated with the Sorin 3T Heater/Cooler machines. Damage or modification of materials and electronics may interfere with the primary activity of the machines, making LTP an unsuitable candidate for sterilization, and therefore must be understood. Suggested Majors (open for modification): BME x 1, ME x 2, EE x 1, Mat Sci x 2 Potential Deliverables (open for modification): 1) Prototype of a plasma delivery system that can be used with the Sorin 3T Heater/Cooler machine. 2) Demonstration of safe plasma generation inside the machine. 3) Report outlining background research, different plasma delivery concepts that were considered, reasons for choosing the final delivery system design 4) Report outlining the effects of LTP on the materials and electronics that constitute the Sorin 3T Heater/Cooler machine. 5) Assessment of suitability of LTP delivery system for Sorin 3T Heater/Cooler machine and other hospital tools of interest for sterilization purposes.

Requested Dept.: Bio, Electrical, MatSci, Mechanical

Requirements: Intellectual

Low-temperature plasma sterilization of medical equipment: the Sorin 3T Heater/Cooler


PSU CIMP-3D 1

Contact: Ted Reutzel

Address: 230 Innovation Park, State College, PA 16803

Project Title: Design and Prototyping of an Improved Powder Feeder System for Additive Manufacturing

Description: Additive manufacturing, also known as 3D printing, involves depositing a layer of fine metallic powder and then melting it layer-by-layer to create a solid part. Directed energy deposition systems for additive manufacturing, like the Optomec LENS (laser engineered net shape) system available in Penn State’s Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D, www.cimp-3d.org), use a powder feeding process whereby a reservoir of powder is stored in a hopper next to the machine and then fed into the machine and blown into the deposition area through four small nozzles, which are then melted by the laser (see figure). Because of the distance the powder has to travel and the mechanism for controlling the rate of powder flow, it is difficult to utilize the dual powder feeders available with the Optomec LENS system to their fullest potential, i.e., it is difficult to make functionally-graded components that combine multiple metallic alloys into a single component. Switching between powders takes 5-10 seconds to clear the line, making it difficult to vary powders within a given layer. Also, fine tuning and control of the amount of powder being fed into the system is limited, reducing one’s ability to blend alloys together from the two different powder feeders on the system. We seek a capstone design team that will help develop new concepts for an improved powder feeding system for the Optomec LENS system in Penn State’s CIMP-3d. To accomplish this, the team shall: (1) analyze the existing powder feeding system on the Optomec LENS system in CIMP-3D, (2) perform a patent search on comparable powder feeding systems and review existing literature and other powder feeding systems, (3) generate 10-20 concepts for improving the powder feeding system, (4) select the best idea and develop a working prototype, (5) test and demonstrate the controllability of the prototype powder feeding system using two common metallic powders (provided by CIMP-3D). Upon completion of the project, the team will provide a detailed report, including a costed bill of materials and CAD drawings, of the prototype system along with analysis of the test results and recommendations for future improvements.

Requested Dept.: Industrial, Mechanical

Requirements: Intellectual

Design and Prototyping of an Improved Powder Feeder System for Additive Manufacturing


PSU CIMP-3D 2

Contact: Tim Simpson & Andrew Armstrong

Address: 209 Leonhard Building, University Park, PA 16803

Project Title: 3D Printing at Sea

Description: What happens when you are on a boat at sea and a part breaks? Hopefully you have a spare on hand or can rig up a fix, but if not, wouldn’t it be nice to 3D print a replacement part? It’s easy to bring a MakerBot, laptop, and spare filament on a boat to print replacement parts if needed, but how well will a 3D printer work on a rocky ocean? What impact do rolling, pitching, yawing, heaving, surging, and slamming have on print quality on a boat? In this project, we seek a team of students to help us explore and quantify what we might encounter when 3D printing a part on a boat at sea. Specifically, the team will: 1. Review related literature on 3D printing at sea and on boats – What’s been done? What are the advantages? What are the disadvantages? What are the key issues to overcome? 2. Develop a set of 4-6 “wave profiles” to simulate different ocean conditions for 3D printing at sea 3. Develop a set of 2-4 test parts that might be 3D printed while on a boat at sea 4. Simulate those “wave profiles” using the six-degree-of-freedom driving simulator at the Penn State Larson Transportation Institute 5. Install and run a small 3D printer in the driving simulator at the Penn State Larson Transportation Institute 6. Monitor and quantify the performance of the 3D printer for each of the “wave profiles” for each of the test parts 7. Document and analyze the results and make recommendations to improve 3D printing at sea 8. (Stretch goal) Design, implement, and demonstrate a method to improve 3D printing for one of the “wave profiles”

Requested Dept.: Industrial, Mechanical

Requirements: none


PSU CIMP-3D 3

Contact: Wes Mitchell

Address: 230 Innovation Boulevard, University Park, PA 16802

Project Title: Lightweight Quadcopter: Novel Designs Enabled by Metal Additive Manufacturing

Description: Quadcopters are a type of unmanned aerial vehicle that have become ubiquitous in the past few years. They are used in recreational, commercial, research, and military/law enforcement applications. Their maneuverability and ease of operation make them particularly useful for photography, videography, surveillance, mapping, and so forth. The airframe of a typical quadcopter seen today is a fixed design constructed from metal, plastic, and/or carbon fiber. There are trade-offs made between weight, stiffness, and cost. Recent developments in metal additive manufacturing (AM) have enabled very stiff, lightweight, and modular (configurable) truss structures to be created (see https://robotbike.co and http://www.divergent3d.com/). Implementing these techniques into a quadcopter could lead to an overall better airframe design. By using carbon fiber tubes to construct the main airframe shape and joining the tubes together with custom designed metal joints at their intersections, a very simple yet stiff structure can be created. The vehicle could also be quickly altered or redesigned for other applications by simply using different length tubes and new joints. There are many advantages that could be exploited once a prototype quadcopter has been built and tested. Penn State’s Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) seeks a team of students to design, build, and fly a lightweight quadcopter using hybrid construction techniques (carbon tube/metal AM joints). This quadcopter will serve as a demonstration piece showcasing advanced construction techniques enabled by AM technology. Project Deliverables: 1. Summary table of existing quadcopter designs and technology 2. Quadcopter design including configurable metal AM joint (CAD file) 3. Schematic of electronic design 4. Constructed quadcopter 5. Video of test flight 6. Detailed report and documentation If time allows: 7. Derive governing equations of quadcopter motion and control model 8. Research bonding and devise a design of experiments to test a metal AM/carbon tube joint

Requested Dept.: CSE, EDG, ESM, Electrical, Industrial, Mechanical

Requirements: none


PSU Dept. of Architecture

Contact: Dan Willis

Address: Stuckeman Building, University Park, PA 16802

Project Title: Designing a System of Prefabricated Parts for ADA-compliant Residential Wheelchair Ramps

Description: Designing a System of Prefabricated Parts for ADA-compliant Residential Wheelchair Ramps Sponsor: Penn State Stuckeman School of Architecture and Landscape Architecture Contact: Dan Willis, Professor of Architecture (dew2@psu.edu) Project Description: This project is a continuation of a Learning Factory project from last spring. The LF team from 2016 developed a design and fabricated a prototype of a system for the prefabrication of residential wheelchair ramps. While their project was very successful (they took a second place award at the Spring 2016 LF Showcase), aspects of their design still need to be developed in order to qualify for a potential patent, or be manufactured in quantity. In addition, the basic design should be further developed into a system that is adaptable to different styles of residential architecture. This project would build on the previous design, but concentrate on detailing the ramp structure, specifying all materials, and developing the design of all connectors and hardware. Ideally, an animated video of a typical ramp installation and assembly, as well as an illustrated catalog of various styles/appearances, would be part of the spring 2017 LF team’s final report and/or presentation. The vast majority of residential wheelchair/access ramps in the United States are custom built, on site, generally from pressure-treated lumber. The cost and quality of these structures varies widely, and their expected lifespan is only about ten to fifteen years. For the elderly or disabled who need to modify their homes for accessibility, there are very limited options available. Many of these people have little knowledge of construction and may fear being taken advantage of by unscrupulous or incompetent contractors. While there are some companies that produce modular prefabricated ramps for residential markets, these are often very industrial looking, made of aluminum, and incompatible with most residential architecture. The goal of this project is to design a durable and affordable system for the construction of residential wheelchair ramps. Using the spring 2016 LF team’s design as a starting point, different materials and combinations of materials should be explored, as well as the possibility of basing the improved system on related existing products, such as Trex or TimberTech decking systems, systems for prefabricated boat docks, etc. Alternative "styles" of ramp should also be explored, so that the system would allow homeowners to choose a ramp style compatible with the appearance of their house or neighborhood. Deliverables should include accurate drawings and details of the new system, material specifications and assembly instructions, and a catalog of possible styles/appearances and applications. A full-size prototype section of a ramp was constructed by the previous team, and it is currently housed in Stuckeman Building. The 2017 may wish to modify or experiment with the prototype, possibly by transporting it to the Learning Factory shop. The LF team will need to become familiar with applicable sections of ADA accessibility regulations and the International Building Code/International Residential Code.

Requested Dept.: EDG, MatSci, Mechanical

Requirements: Intellectual

Designing a System of Prefabricated Parts for  ADA-compliant Residential Wheelchair Ramps


PSU Engineering Leadership Development

Contact: Mike Erdman

Address: 213 Hammond, University Park, PA 16802

Project Title: Baobab Pulp Processor

Description: Baobab fruit grows in sub-Saharan Africa, and is well known as a highly nutritious source of vitamins and minerals. Unfortunately, the local processes for creating usable powder from the fruit is inefficient and not sanitary. Penn State has been developing technology to process the highly nutritious baobab pulp into a fine powder for use in foods or sale as an export. The current design of the Penn State machine has evolved over the past several years, and has been distributed to co-operatives, individuals, and small start-up companies across Africa. Feedback from the users has pointed out certain shortcomings in the design and manufacture of the machine, such as significant loss of powder to the atmosphere, weaknesses in certain parts, and an inability to accurately reproduce the machine due to 'hand-working' certain parts. The team will review the current design, identify and rank improvement opportunities, recommend and design changes, and build/test an improved prototype unit. The deliverables will include the prototype unit(s), all design files and files associated with automated cutting of parts, as well as a final report documenting the design decisions and test results.

Requested Dept.: EDG, ESM, Industrial, Mechanical

Requirements: none

Baobab Pulp Processor


PSU eSportbike

Contact: Tim Cleary

Address: 201 Transportation Research Building, University Park, PA 16802

Project Title: PSU eSportbike: Motor & Controls

Description: PSU eSportbike is a Penn State club currently building a fully electric motorcycle for competitive racing. Building off of a new 2015 BMW S1000RR frame, we currently have the battery pack & BMS system designed. Requiring an electric motor and controller to propel the bike, PSU eSportbike needs assistance in selecting the motor and motor controller, generating and implementing the logic and appropriate programs for the control system and related embedded microelectronics, and finally installing it for turn key operation. It is expected that this project will incorporate many aspects of electrical engineering such as energy conversion, electronics, programming, control systems, signal processing, and more.

Requested Dept.: Energy, Electrical

Requirements: none

PSU eSportbike: Motor & Controls


PSU Fleet Operations

Contact: Rob DeMayo

Address: 5 Fleet Operations Building, University Park, PA 16802

Project Title: PSU Fleet Operations Efficiencies Improvements

Description: 1. Fleet Operations reports to David Grey, Sr. VP of Finance and Business. 2. There is an ongoing business and structural review of operations to identify operational opportunities for improvement (end of February report due). 3. Fleet Operations manages: a.466 cars (270 are “permanently assigned), b.200 mixed use i.e. vans, buses, special purpose vehicles), c.Approximately 100 vehicles are “not scheduled”. 4. Vehicles are dispatched by Fleet Operations as required by occasional as well as repeat users. 5. Vehicles are re-fueled, cleaned and parked when returned. 6. Legacy (i.e. in-house) fleet management software (15-20 years old) is used to manage day-to-day operations. 7. Car management efficiency improvement opportunities exist and are not limited to the following areas: a. Determining utilization rates and managing these metrics for improvement, b. Developing Standard Operating Procedures (SOP’s), Checklists and Training Manuals to standardize operations c. Improved fleet management software/systems to dynamically track and improve management of operational efficiencies, d. Forecasting demand by class of vehicle to better manage labor requirements (e.g. so vehicles are not staged so far in advance they require re-washing prior to pick-up), 8. Historical data may be available for evaluation of operational improvements, depending on actual data needs. 9. Sponsor contact will be Rob DeMayo, Charlie Purdum will be Faculty Advisor. 10. The PSU Industrial Engineering project team will provide the initial project proposal, timeline, weekly updates, interim and final reports to project sponsor, Rob DeMayo. 11. PROJECT FUNDING WILL BE FROM SEE 360 INITIATIVE AT A RATE OF $1,750.

Requested Dept.: Industrial

Requirements: none


PSU GridSTAR Center 1

Contact: David Riley

Address: 104 Eng. Unit A, University park, PA 16802

Project Title: Net Zero Tiny House Trailer Team 1

Description: The purpose of this project is to design a mobile net-zero structure that includes off-grid solar electric and thermal systems, functional kitchen, and storage spaces. The project will utilize an existing auto-trailer and maximized incorporation of re-used and reclaimed materials. When completed, the mobile structure will be utilized as a demonstration structure highlighting tiny house building methods and technical systems, as well as a support structure for volunteer activities. Deliverables include: (1) Sketch-up prototype, (2) Design drawings and details, (3) Structural system design and details, (4) Electrical, Mechanical, and Plumbing schematics, and (5) full scale mock-up on existing trailer.

Requested Dept.: Energy, EDG, ESM, Electrical, Industrial, Mechanical

Requirements: none

Net Zero Tiny House Trailer Team 1


PSU GridSTAR Center 2

Contact: David Riley

Address: 104 Eng. Unit A, University Park, PA 16802

Project Title: Net Zero Tiny House Trailer Team 2

Description: The purpose of this project is to design a mobile net-zero structure that includes off-grid solar electric and thermal systems, functional kitchen, and storage spaces. The project will utilize an existing auto-trailer and maximized incorporation of re-used and reclaimed materials. When completed, the mobile structure will be utilized as a demonstration structure highlighting tiny house building methods and technical systems, as well as a support structure for volunteer activities. Deliverables include: (1) Sketch-up prototype, (2) Design drawings and details, (3) Structural system design and details, (4) Electrical, Mechanical, and Plumbing schematics, and (5) full scale mock-up on existing trailer.

Requested Dept.: Energy, EDG, ESM, Electrical, Industrial, Mechanical

Requirements: none

Net Zero Tiny House Trailer Team 2


PSU Hershey Medical Center 1

Contact: Abraham Mathews

Address: Hershey Medical center, Hershey, PA 1700

Project Title: Precision endoscopic suturing device

Description: Construct prototype that can be used in patients based on the concepts and tool tip prototype previous developed( Available with Mary Frecker PhD, dept. of mechanical engineering). The device will be passed through 2.8 to 3.3 mm scope channels to place sutures inside a patients body allowing incision less surgery.

Requested Dept.: Bio, Mechanical

Requirements: none


PSU Hershey Medical Center 2

Contact: Dr. Matthew Moyer, MD and Brad Hanks

Address: 314 Leonhard Bldg, University Park, PA 16802

Project Title: Endoscopic Ultrasound Guided Radiofrequency Ablation Probe for Pancreatic Cancer

Description: Removal of isolated abdominal tumors by resective surgery is the preferred approach when the benefit of major surgery is balanced with the risk of operating on a mass which may have already disseminated and the risks of major surgery. Not all patients can tolerate major surgery or are agreeable to it. Endoscopic ultrasound(EUS)-guided tumor ablation has been increasingly used as a minimally invasive alternative to eliminating gastrointestinal tumors. However, currently available EUS-guided ablation modalities (principally alcohol ablation and radiofrequency ablation (RFA)) have limitations in efficacy due to the risk of incomplete tumor destruction. Conversely, almost all other areas of oncology embraced the role of multi-modality treatment to increase rates of oncologic success. The Chimera Project is the development of a minimally invasive, dual-energy, EUS-guided, ablation device for the treatment of isolated pancreatic, hepatic, and other abdominal tumors which. This device can facilitate combining RFA and stereotactic body radiation therapy (SBRT), taking advantage of radiation’s known synergy with hyperthermia by providing further tumor cell kill at the periphery of the RFA burn zone. A critical part of designing and marketing new medical technology is the ability to showcase your product and give users a hands on feel. The capstone design team will be responsible for developing an interactive display which enables doctors to feel and visualize the technology. The work of the capstone students will be shown at future conferences and presentations, introducing this technology to doctors and industry as a future minimally invasive treatment option for a variety of abdominal cancers. Deliverables 3 Functional displays with the following characteristics - Durable to withstand many users - Portable - Self-explanatory design, user friendly - Highlights unique features of the technology Complete design description including - CAD parts - engineering drawings - Manufacturing processes utilized - Detailed list of all materials, part numbers, etc. necessary to rebuild the display

Requested Dept.: Bio, ESM, Industrial, Mechanical

Requirements: none

Endoscopic Ultrasound Guided Radiofrequency Ablation Probe for Pancreatic Cancer


PSU IME 1

Contact: Sanjay Joshi

Address: 310 Leonhard Building, University Park, PA 16802

Project Title: Development of a Variable Diameter Nozzle for 3D Printing

Description: Background: ----------- While there are several different types of 3D printing and additive manufacturing (AM) technologies, fused deposition modeling (FDM) has established itself as the most prevalent in industry due to its relatively low cost, simplicity, and adaptability. The FDM process begins like any other AM process – the part which you would like to print is deconstructed into layers using a “slicing” algorithm, the part information from each layer is converted into the tool path for each layer, in the form of G-code, and the G-code is fed into the 3D printer. Plastic feedstock is then melted and extruded out of a nozzle onto a build platform layer-by-layer in patterns described by the G-code. Through the addition of subsequent layers, a 3D part is constructed. Motivation: ----------- Up until recently, 3D printing has been used almost exclusively for prototyping, creating parts that are suitable for form, fit, and demonstration purposes but not as final products. A crucial component for transitioning AM to produce final products is decreasing the build time for additively manufactured parts. While platforms like ORNL’s Big Area Additive Manufacturing (BAAM) printer address this issue, it does so at the cost of decreased feature resolution. This is a result of the large extrusion nozzle diameter that is used to meet the flow rates required to quickly produce parts. A solution to this issue is a nozzle in which the diameter could be varied during the print, allowing the user to maintain high deposition rates without a major loss of feature resolution. BAAM-like printers have the most to gain from this innovation with a potential to increase feature resolution and improve mechanical strength. Smaller, commercial FDM printers would benefit from increased build speeds and improved mechanical strength. To take advantage of variable diameter nozzle, however, existing slicing and toolpath algorithms need to be developed to accommodate changes in track width and height. Eventually, the toolpath algorithm will be able to optimize the build path by continuously transitioning between different nozzle diameters. Project Scope: -------------- Work has already been done to prototype a mechanical system capable of extrusion through a variable diameter nozzle; however, a new toolpath algorithm must be developed to make the most of the potential benefits of variable diameter extrusion. For this project, we seek two (2) teams that will work together on the following: 1. Understand the new design capabilities made possible by variable diameter extrusion. 2. Conduct a patent search and literature review of variable diameter nozzles as well as slicing and toolpath algorithms 3. Refine the variable diameter nozzle extruder prototype and integrate it onto an existing FDM system 4. Understand the inner workings of open source slicing and toolpath algorithms for FDM (Slic3r, Cura, etc.) 5. Modify or develop a toolpath algorithm to enable variable diameter extrusion on a single layer a. Initially discrete diameter changes b. Transition to continuous diameter changes c. Allow for circular and rectangular nozzle geometries 6. Show proof of concept using a FDM printer with dual extrusion heads with different diameter nozzles. One team will focus primarily on the design and development of the variable diameter nozzle and its integration with a FDM system. The second team will focus primarily on the slicing and toolpath algorithms. The two teams will need to coordinate frequently to ensure successful project completion. Deliverables will include sketches, drawings, CAD models, source code, prototypes, and detailed documentation for system integration and algorithm implementation.

Requested Dept.: CompSci, CSE, ESM, Electrical, Industrial, Mechanical

Requirements: Intellectual


PSU IME 2

Contact: Sanjay Joshi

Address: 310 Leonhard Building, University Park, PA 16802

Project Title: Development of a Variable Diameter Nozzle for 3D Printing

Description: Background: ----------- While there are several different types of 3D printing and additive manufacturing (AM) technologies, fused deposition modeling (FDM) has established itself as the most prevalent in industry due to its relatively low cost, simplicity, and adaptability. The FDM process begins like any other AM process – the part which you would like to print is deconstructed into layers using a “slicing” algorithm, the part information from each layer is converted into the tool path for each layer, in the form of G-code, and the G-code is fed into the 3D printer. Plastic feedstock is then melted and extruded out of a nozzle onto a build platform layer-by-layer in patterns described by the G-code. Through the addition of subsequent layers, a 3D part is constructed. Motivation: ----------- Up until recently, 3D printing has been used almost exclusively for prototyping, creating parts that are suitable for form, fit, and demonstration purposes but not as final products. A crucial component for transitioning AM to produce final products is decreasing the build time for additively manufactured parts. While platforms like ORNL’s Big Area Additive Manufacturing (BAAM) printer address this issue, it does so at the cost of decreased feature resolution. This is a result of the large extrusion nozzle diameter that is used to meet the flow rates required to quickly produce parts. A solution to this issue is a nozzle in which the diameter could be varied during the print, allowing the user to maintain high deposition rates without a major loss of feature resolution. BAAM-like printers have the most to gain from this innovation with a potential to increase feature resolution and improve mechanical strength. Smaller, commercial FDM printers would benefit from increased build speeds and improved mechanical strength. To take advantage of variable diameter nozzle, however, existing slicing and toolpath algorithms need to be developed to accommodate changes in track width and height. Eventually, the toolpath algorithm will be able to optimize the build path by continuously transitioning between different nozzle diameters. Project Scope: -------------- Work has already been done to prototype a mechanical system capable of extrusion through a variable diameter nozzle; however, a new toolpath algorithm must be developed to make the most of the potential benefits of variable diameter extrusion. For this project, we seek two (2) teams that will work together on the following: 1. Understand the new design capabilities made possible by variable diameter extrusion. 2. Conduct a patent search and literature review of variable diameter nozzles as well as slicing and toolpath algorithms 3. Refine the variable diameter nozzle extruder prototype and integrate it onto an existing FDM system 4. Understand the inner workings of open source slicing and toolpath algorithms for FDM (Slic3r, Cura, etc.) 5. Modify or develop a toolpath algorithm to enable variable diameter extrusion on a single layer a. Initially discrete diameter changes b. Transition to continuous diameter changes c. Allow for circular and rectangular nozzle geometries 6. Show proof of concept using a FDM printer with dual extrusion heads with different diameter nozzles. One team will focus primarily on the design and development of the variable diameter nozzle and its integration with a FDM system. The second team will focus primarily on the slicing and toolpath algorithms. The two teams will need to coordinate frequently to ensure successful project completion. Deliverables will include sketches, drawings, CAD models, source code, prototypes, and detailed documentation for system integration and algorithm implementation.

Requested Dept.: CompSci, CSE, ESM, Electrical, Industrial, MatSci

Requirements: Intellectual


PSU IME 3

Contact: Soundar Kumara, Hui Yang

Address: 310 Leonhad building, University Park, PA 16802

Project Title: Design and possible implementation of Lego Factory

Description: There are several prototype projects on You-Tube which give people an idea on how to build a prototype factory using Legos. In this project we want to identify a product, possibly replicate the FAME Lab as a factory, interface machines through Internet of Things (IoT) architecture and observe in real-time how we can make the factory operational. In this IE480 effort we want to generate a design with all the details to address the aspects related to: 1. What are machine level connections (connectivity) issues 2. What are information level connections (Communication) issues 3. What are data level issues(sensors) 4. What are the propagation and system level  (integration) issues 5. What are decision making (optimization) issues 6. What are control (real-time and quasi real-time) issues 7. What are continuity (supply chain) issues This is a major undertaking. However, we will build a small prototype with a minimum of two machines talking to each other with in the design that is developed through the students’ efforts. We will also attempt to build a simulation of the factory and show first level interface with the lego factory.

Requested Dept.: Industrial

Requirements: none


PSU IME 4

Contact: Soundar Kumara, Hui Yang

Address: 310 Leonhard building, University Park, PA 16802

Project Title: Internet of Things Enabled Legacy Machines

Description: The objective of this project is to identify the important components of interconnecting legacy machines in the FAME lab using Internet of Things (IoT) concept. This project will help in establishing IoT based communication infrastructure so that any machine (in this case a legacy machine) as a node in the internet. In a nutshell the objective of the project is to make the machines and producst talk to each other. The proposed project will explore what and how of this. We will provide the IoT hardware. Students need to figure out how to make the communication feasible and demonstrate it with at least two machines and one part. The Fame lab is a real manufacturing facility for teaching and research. It houses a diverse set of manufacturing processes including casting, welding, machining, forming, injection molding, and assembly systems. In particular, the Fame lab houses a set of legacy machines dated back to 1965. As shown in Fig. 1, the area of manual machining has 3 Bridgeport vertical milling machines, 2 drill presses, and 7 LeBlond lathes. Our vision is to see the IoT hardware installed in these legacy machines for in-situ process monitoring and control of the shopfloor.

Requested Dept.: Industrial

Requirements: none


PSU IME 5

Contact: Ed De Meter

Address: 310 Leonhard building, University Park, PA 16802

Project Title: Automated Lab Safety System

Description: With increasing student enrollment and increasing university documentation requirements, it is difficult to track and monitor training and safety certification of students who utilize the FAME lab for both class room instruction and project work. To solve this problem, the Department of Industrial & Manufacturing Engineering wishes to develop an on-line laboratory safety and training management system. This system will allow department staff members to track laboratory safety certifications and equipment training certifications earned by students. It is expected that the student engineering team will meet with department faculty and staff to gather input for system requirements. The engineering team will then design and prototype the system in a software language to be specified by the department. This software will then be integrated into the IE intranet by department staff at a future date.

Requested Dept.: Industrial

Requirements: none


PSU Institute for CyberScience 1

Contact: Wayne Figurelle

Address: 224D Computer Building, University Park, PA 16802

Project Title: Portable Computation Display Wall

Description: Recently, the institute for CyberScience, and the Institute for Gravitation and the Cosmos conducted a summer camp for high school students in Centre County to learn about a brand new field: Gravitational wave astronomy. http://www.centredaily.com/news/local/education/article91379802.html As part of the camp, students built a miniature high throughput computing cluster capable of analyzing data in realtime for searches for gravitational waves. We would like to turn this miniature cluster into a display wall that is approximately 4'x8' capable of supporting a 55inch LED monitor and approximately 14 micro form factor computers along with networking and power. We would like to have this display able to be mounted on a wall or be free standing. At first we would like to host this on Penn State campus, but in the long run we would like to make it available as an outreach tool to other universities. This project will require mechanical engineering consultation, but we would also like a team to consider the aesthetics of the design and possibly incorporating relevant student art into the design.

Requested Dept.: CompSci, CSE, EDG, Electrical, Industrial, Mechanical

Requirements: none


PSU Institute for CyberScience 2

Contact: Adam Lavely and Wayne Figurelle

Address: Computer Building , University Park, PA 16802

Project Title: Repurposing Decommissioned ICS Clusters

Description: ICS is in the process of decommissioning several clusters as a part of the transition to the newer ACI machines. ICS hardware was successfully used by a CMPEN 482 / EDSGN 581 project in Fall 2016 to create a prototype of a cluster for use in middle and high schools. The prototype consists of a working cluster with a preliminary software stack. A Spring 2017 Capstone project is proposed to further the development of the prototype and to design the deployment method. This project will be done in conjunction with an EDSGN 582 group, CSATS and ICS. ICS proposes that the next stage of this process be an extension of the existing capability and the design of the deployment method. The current software stack can be expanded to include more topics of interest to students and teachers, e.g. parallel operation and code development, and to include lesson planning and student progress tracking within databases. Additionally, the user interface will need to be optimized for various methods of interacting with the cluster. ICS will be working with CSATS to train teachers on how to use for classroom activities. The project will include helping to create the necessary documentation and a deployment plan. While there is a large amount of hardware available, the varying components may necessitate the design of multiple cluster versions for equivalent compute power. The project will also include the development of a QA test harness to verify that the clusters are operating correctly, both when initially put together as well as for teachers working with the clusters with students.

Requested Dept.: CompSci, CSE, ESM, Industrial

Requirements: none


PSU Institute for Natural Gas Research 1

Contact: Monty Alger

Address: 101 Hosler Building, University Park, PA 16802

Project Title: Carbon Index and Real-time End User Carbon Measurements - Team 1

Description: Background Successful transition to a future low carbon energy infrastructure requires balance of both economic and environmental goals as shown in Figure 1. Public sentiment has shifted markedly in recent years favoring much more emphasis on Sustainability. While there is agreement on overall future direction, there is a need for alignment of various stakeholders. Many proposed sustainable solutions do not have required economic return to justify market investment. Alignment of innovation, investment and policy will permit debate and alternatives that can be implemented through a public / private partnership engaging all key stakeholders as shown in Figure 2. At the recent Penn State Energy Days, Dr. Kristina Johnson, CEO of CubeHydro and former Undersecretary of DOE, suggested there is a need for the equivalent of an Intensive Care Unit (ICU) checklist for transforming our energy infrastructure. With student, faculty, and stakeholder engagement, Penn State is well positioned to design and implement such an “Energy System Transformation” methodology as an open source best practices model. Such an approach would use an “outside-in” design to establish baseline performance, set target goals, and identify options for implementing changes in systems ranging in scale from individual buildings to university campuses and communities and beyond to private and governmental organizations. Figure 2 captures the key levers of innovation, investment, and policy. In order to begin providing the “Measurements,” we propose to define and create a carbon intensity index based on existing EIA data and publish the index on the INGAR website. Then other measures of environmental performance would be created such as the water footprint, energy use and operating cost components. Next we would initiate small scale, real-time measurement for environmental and economic outputs on Penn State’s campus and publish them on the INGAR website. Use of “real-time” measurements would provide a gauge of performance and highlight the major improvement opportunities. These measurements would be available in a consistent, global format, relying on big data and cloud-based platforms.

Requested Dept.: CompSci, CSE, Energy

Requirements: none


PSU Institute for Natural Gas Research 2

Contact: Monty Alger

Address: 101 Hosler Building, University Park, PA 16802

Project Title: Carbon Index and Real-time End User Carbon Measurements - Team 2

Description: Background Successful transition to a future low carbon energy infrastructure requires balance of both economic and environmental goals as shown in Figure 1. Public sentiment has shifted markedly in recent years favoring much more emphasis on Sustainability. While there is agreement on overall future direction, there is a need for alignment of various stakeholders. Many proposed sustainable solutions do not have required economic return to justify market investment. Alignment of innovation, investment and policy will permit debate and alternatives that can be implemented through a public / private partnership engaging all key stakeholders as shown in Figure 2. At the recent Penn State Energy Days, Dr. Kristina Johnson, CEO of CubeHydro and former Undersecretary of DOE, suggested there is a need for the equivalent of an Intensive Care Unit (ICU) checklist for transforming our energy infrastructure. With student, faculty, and stakeholder engagement, Penn State is well positioned to design and implement such an “Energy System Transformation” methodology as an open source best practices model. Such an approach would use an “outside-in” design to establish baseline performance, set target goals, and identify options for implementing changes in systems ranging in scale from individual buildings to university campuses and communities and beyond to private and governmental organizations. Figure 2 captures the key levers of innovation, investment, and policy. In order to begin providing the “Measurements,” we propose to define and create a carbon intensity index based on existing EIA data and publish the index on the INGAR website. Then other measures of environmental performance would be created such as the water footprint, energy use and operating cost components. Next we would initiate small scale, real-time measurement for environmental and economic outputs on Penn State’s campus and publish them on the INGAR website. Use of “real-time” measurements would provide a gauge of performance and highlight the major improvement opportunities. These measurements would be available in a consistent, global format, relying on big data and cloud-based platforms.

Requested Dept.: CompSci, CSE, Energy

Requirements: none


PSU Made by Design Lab 1

Contact: Nicholas Meisel

Address: 213J Hammond Building, University Park, PA 16802

Project Title: Design of an Adaptable Ejection Mechanism for a 3D Printing Vending Machine

Description: In recent years, interest in additive manufacturing (AM, also known as 3D printing) has grown exponentially at educational institutions. K-12 schools have embraced the technology as a way to engage students with STEM principles and enable problem-based learning. Likewise, universities have begun to invest in access to AM to support student prototyping and foster design creativity. However, providing broad access to AM technology presents numerous challenges, including concerns over student safety, maintenance/upkeep challenges, and the ability to provide significant throughput to support wide use. In an attempt to address these challenges, several universities have begun pursuing the idea of 3D printing vending machines. The idea for a 3D printing vending machine was initiated at Virginia Tech with the “DreamVendor,” but quickly gained traction at other universities, such as the University of Texas – Austin. The general workflow for such vending machines is as follows: i) the student designs their desired object in CAD and exports to STL, ii) the student brings their STL file to the vending machine on removable media, iii) the print is initiated through the 3D printer, iv) the printer manufactures the object layer-by-layer until it is completed, v) the printer ejects the part into a collection bin, and vi) the student returns to collect their finished print. However, there are still many challenges associated with such vending machines, especially in consistent, reliable ejection of printed parts. For this project, the student team will be tasked with designing, programming, manufacturing, implementing, and evaluating an ejection mechanism to be used with a 3D printing vending machine. The mechanism must be designed in such a way that it can be adapted to a variety of both present and future desktop-scale 3D printers, due to the rapid growth of the industry. Success will be determined based on the i) the ability of the ejection mechanism to consistently remove printed parts, ii) the absence of damage caused by the ejection mechanism to the printed parts or the build platform, and iii) the ability to rapidly adjust the ejection mechanism to function with different commercially-available or open-source desktop 3D printers. The designed ejection mechanism will be a key component for future projects focused on designing additional elements of the vending machine (e.g., user interface, safety system, collection mechanism). This project is sponsored by the Made By Design Lab, a Penn State research group focused on the intersection of design and additive manufacturing. The lab is directed by Dr. Nick Meisel, Assistant Professor of Engineering Design and Mechanical Engineering.

Requested Dept.: EDG, Mechanical

Requirements: none


PSU Made by Design Lab 2

Contact: Nicholas Meisel

Address: 213J Hammond Building, University Park, PA 16802

Project Title: Design of a Filament Recycling System for Polymer 3D Printing

Description: The rise of additive manufacturing (AM, also known as 3D printing) has caused a seismic change to the way in which engineers prototype their designs. Rather than relying on skilled craftspeople to translate objects from the digital design realm to a physical model, the prototyping process has become as simple as saving a designed CAD model as an STL file, importing it to a 3D printer, and waiting for the system to automatically create an accurate representation of the designed product. However, the design process is inherently iterative, with newer printed products often being required as designs are changed. Rather than simply disposing of the obsolete prototype, the thermoplastic material used for printing has the potential to be recycled into new filament, thus reducing waste and raw material cost. This recycling principle may be applied to any and all cast-off thermoplastic material from printing, including that from rafts, structural supports, or failed prints. However, thermoplastic recycling is not yet ubiquitous in AM, likely due to a lack of inexpensive, consistent, easy-to-use options. For this project, the student team will be tasked with designing, manufacturing, implementing, and evaluating a system for recycling cast-off thermoplastic material to be reused in a desktop-scale 3D printer. The system must be designed in such a way that it can take cast-off waste thermoplastic material, re-pelletize it, extrude it into filament form, and re-spool it for printing. Success will be determined based on i) the ability of the system to create consistent pellets from a variety of cast-off forms, ii) the consistency of the diameter of the newly extruded filament, iii) the speed at which new filament can be created and re-spooled, and iv) the quality of final printed parts created from the recycled filament. Additional stretch goals include an adjustable system capable of creating filaments of different diameters (e.g., 1.75mm, 3mm) to accommodate different 3D printers. This project is sponsored by the Made By Design Lab, a Penn State research group focused on the intersection of design and additive manufacturing. The lab is directed by Dr. Nick Meisel, Assistant Professor of Engineering Design and Mechanical Engineering.

Requested Dept.: EDG, Industrial, Mechanical

Requirements: none


PSU MatSE Department

Contact: Elizabeth Kupp

Address: 212 Steidle Building, University Park, PA 16802

Project Title: User equipment control and logging software development

Description: The MatSE department has a suite of equipment (e.g., furnaces, mechanical testing machines, analytical, processing) for which we require computer log-in access to ensure that users have received the proper laboratory safety and equipment use training. We need a software package that will allow us to set up this log-in access on a case-by-case basis, in addition to logging user data (e.g., date, time on machine). The software will allow us to track usage for planning and charge-out purposes and ensures that the students using the equipment are properly trained and maintain the equipment correctly.

Requested Dept.: CompSci, Electrical, MatSci

Requirements: none


PSU Mechatronics

Contact: Chris Rahn

Address: 150A Hammond, University Park, PA 16803

Project Title: Chest Band Energy Harvesters

Description: Breathing is the most consistent source of kinetic energy in the body and the human chest has a circumferential displacement of about 2.5cm while breathing. The goal of this project is to use the displacement of the chest to rotate an electromagnetic (EM) generator to produce an average power greater than 2 mW. The voltage from the EM device is rectified and the electrical energy is stored in a capacitor. The energy is then used to power the Polar H7 heart rate monitor. The design team is expected to improve upon an existing harvester design that drives the output shaft of a servomotor as the user inhales by using a strap that encircles the chest. A rubber band returns the servomotor to its starting position when the user exhales. The device is mounted on a back support belt using Velcro which is worn around the chest. Tasks and Considerations The new device will function on the same principle as the previous device but it will be more refined and optimized. The device should be tested while the user is sitting, walking, and running. The goal is to produce an average power greater than 2 mW and power the Polar H7 heart rate monitor. Mechanical A proper servomotor must be selected such that the gearing allows the user to rotate the internal rotor by applying torque to the output shaft. The profile of the device must be minimized for ergonomics and must be wearable for different body types. The Velcro belt used to mount the servomotor to the body in the current design applies an uncomfortable amount of pressure on the chest, so a new mounting method is required. The strap can be looped around the chest multiple times to increase displacement. The servomotor will require a return mechanism to return it to its initial position once the user exhales. Electrical A rectification circuit must be designed to convert the AC voltage to DC. The circuit must also incorporate a capacitor that will be charged by the rectified power. Alternatively, the circuit can be designed to disconnect during exhale with a half-wave rectifier (diode). This method also allows the use of a weaker return mechanism because removing the load allows the servomotor to rotate with less torque (due to the high electromechanical coupling of the servomotor). A weaker return mechanism would reduce the overall mechanical resistance and increase user comfort, but also reduces the average power generated. The rectification circuit should interface with the Polar H7 at the battery electrodes. The Polar H7 uses a CR2025 coin cell battery and strap to measure heart rate and transmit the data via Bluetooth.

Requested Dept.: CSE, Electrical, Mechanical

Requirements: none

Chest Band Energy Harvesters


PSU MNE 1

Contact: Guha Manogharan

Address: 232 Reber Building, State College, PA 16802

Project Title: Design and Development of A Closed-Loop Metal AM System

Description: Although, there is growing hype around additive manufacturing (AM) and its potential as a disruptive advanced technology, the cost of a metal AM system is in the range of $350,000 - $1M. This project proposes to develop a low cost metal AM system that would incorporate Tungsten Inert Gas (TIG) welding system as a "directed energy source" for AM fabrication. The major salient feature of this system would be the closed-loop process-monitoring and control system that could incorporate IR and thermocouple sensors to maintain uniform melt pool conditions during deposition to improve part performance. This "3D" system differs from an automated welding unit since the physical configuration will include a multi-axis linear stage and include "dabber" control unit for superalloys of interest to AM community Deliverables include: (1) CAD Assembly of the designed metal AM System, (2) Fabrication of motion-control of metal AM deposition stage, (3) Demonstration of metal AM processing capability and (4) Evaluation of sensor incorporation to improve AM build quality.

Requested Dept.: CSE, MatSci, Mechanical

Requirements: none


PSU MNE 2

Contact: Guha Manogharan

Address: 232 Reber Building, State College, PA 16802

Project Title: Development of Design-Fabrication-Testing Work Flow for Custom Shoulder Joints

Description: The ability to process patient-specific information (CT/MRI/X-ray) to fabricate custom implants has garnered a lot of interests in the growing area of mechanical-biomedical applications. However, most of current research at Hershey Med Center has been limited to virtual models of new implant design. This project will work with an interdisciplinary team of orthopedic surgeons, biomedical specialist and implant designers to develop a new design process to "custom-fit" shoulder implants for patients, evaluate optimal design by incorporation of porous structures, FEA analysis, AM fabrication and simulated testing in a custom rig at Hershey Med Center that replicates a human shoulder joint. Strain gages will be incorporated to test the efficacy of the developed design algorithm on aspetic loosening and fit with CT/MRI data. Deliverables would include: (1) IRB completion to work with CT/MRI/X-Ray Data, (2) Reverse-engineered CAD model of joints, (3) Design of custom implant, (4) FEA model of implant design optimization and (5) Demonstration of AM implant fabrication

Requested Dept.: Bio, Mechanical

Requirements: none

Development of Design-Fabrication-Testing Work Flow for Custom Shoulder Joints


PSU MNE 3

Contact: Steve Carpenter/Zoubeida Ounaies

Address: 157B Hammond Building, University Park, PA 16801

Project Title: Designing DIY Kits to Produce Life-Saving Materials in Response to the Global Water Crisis

Description: Water-related diseases cause millions of deaths annually around the world. Lack of safe drinking water, pervasive disease, and substandard sanitation are known as the global water crisis. Among the most active means of responding to the global water crisis include the production and distribution of point-of-use ceramic water filters manufactured from local materials in communities in need. Since the late 1990s, thousands of the filters have been produced, distributed, and used in the developing and third world. These point-of-use ceramic water filters are designed as low-cost, first responses and temporary solutions to provide clean water in remote areas after natural disasters. The active component in these filters is colloidal silver that attracts and renders inert microbes and other waterborne diseases with 99.9% effectiveness. The colloidal silver is the most expensive element in the filters and is not readily available in communities of need. Reducing the cost to produce the filters would enable wider distribution and improve the health of millions of people annually. In order to make the process more affordable, one solution is to develop DIY fabrication approaches to produce colloidal silver inexpensively from repurposed and local sources. Other materials such as copper, which is abundantly available, inexpensive, and potentially effective against waterborne diseases, could also be produced, which would help millions more people annually through this low-cost approach to filtering clean water. In short, we need to develop an inexpensive DIY approach to producing colloidal silver and colloidal copper to expand the range of affordable responses to the global water crisis. The goals for this project are: (1) research and design DIY approaches to producing colloidal silver and colloidal copper from scrap or inexpensive sources; (2) test the effectiveness of the DIY materials in ceramic water filters in comparison to conventionally-produced water filters enhanced with colloidal silver; and, (3) design an image-based instruction book to accompany the DIY silver and copper kits for end users regardless of culture or language (think step-by-step instruction books used to assemble IKEA furniture or LEGO building sets).

Requested Dept.: Chem, Energy, EDG, ESM, MatSci, Mechanical

Requirements: none

Designing DIY Kits to Produce Life-Saving Materials in Response to the Global Water Crisis


PSU MNE 4

Contact: Paris vonLockette

Address: 160 Hammond Bldg, State Collee, PA 16803

Project Title: MACS Lab: Monitoring and control of 5 and 10kW electromagnets using Labview

Description: Note that this projects requires knowledge and skills in using LabView. Nominally 3 ECE (or others with LabView skills) and 1 ME The Magneto-Active Composites and Structures (MACS) Lab operates 5kW and 10kW electromagnets using manually controlled power supplies. The power supplies are dialed to a current that yields the desired magnetic flux density. Each magnet is cooled by its own recirculating chiller. The goal of this project is to design, purchase and implement a LabView VI and the accordant hardware that enables the user to set a desired magnetic flux density (or time varying flux density), have the magnet system automatically achieve that setting, and monitor important operating temperatures while doing so. The objectives of the project are to 1. Design a LabView VI to monitor, record, and give excessive temperature alerts from multiple thermocouple data sources; 2. Add to the VI the ability to monitor and record data from a Gaussmeter (magnetic flux density meter) having an analog voltage output; 3. Add to the VI the ability to send analog voltage signals, either fixed or time varying, to control a D.C. Power supply; 4. Develop and integrate into the VI some form of feedback control to regulate the power output of the DC power supply such that it accurately produces and/or maintains the fixed or time varying desired magnetic flux density; 5. Provide a final demonstration and documentation.

Requested Dept.: Electrical, Mechanical

Requirements: none


PSU MNE 5

Contact: Tak-Sing wong

Address: N252A Millennium Science Complex, University Park, PA 16802

Project Title: Pulling Water from Thin Air: Design and Characterization of a Portable Fog-Harvesting Machine

Description: Overview: Providing access to clean water is listed as one of the grand challenges for engineering in the 21st century by the US National Academy of Engineering. One of the key issues is the uneven distribution of clean water supply around the globe, particularly in remote regions. To resolve this issue, the proposed project team will be working with the researchers at the Laboratory for Nature Inspired Engineering at Penn State to design and characterize a portable, low-cost and energy efficient fog harvesting machine to collect clean, desalinized water from thin air. Deliverable: The team will involve in the design, fabrication, and characterization of the fog-harvesting machine. Working with the researchers at the Laboratory for Nature Inspired Engineering, the team will build the machine, and quantify the water-collection and energy efficiency of the machine at realistic environmental settings.

Requested Dept.: Electrical, Industrial, MatSci, Mechanical

Requirements: Intellectual


PSU MNE 6

Contact: Joe Sommer

Address: 337 Leonhard Building, University Park, PA 16802

Project Title: Handheld Tribometer to Measure Slip Resistance of Flooring

Description: Falls are the second leading cause of accidental deaths in the United States, and slick floors are responsible for many of these accidents. A slip or fall may occur when there is insufficient traction between the pedestrian’s foot and the walking surface. Slip resistance is related to the flooring, the shoe bottom, and foreign matter between them. Consequently, a tribometer must be able to measure coefficient of friction (COF) under various conditions (static versus dynamic COF, dry versus wet). Unfortunately many current tribometers lack repeatability and are not easy to use. The objective of this project is develop and validate a commercial prototype of a handheld tribometer using a dual beam friction pad to simultaneously measure normal and friction forces with strain gages. This project will expand on a prior M.S. thesis and will require both mechanical and microprocessor design skills.

Requested Dept.: CompSci, Mechanical

Requirements: none


PSU Nittany Lion Inn 1

Contact: Thomas Neely

Address: Nittany Lion Inn, University Park, PA 16802

Project Title: Kitchen Operations Improvement

Description: 1. Food preparation and service challenges exist as a result of serving 2 different dining formats (i.e. menus) from one kitchen. 2. Initial focus will be Kitchen and Whiskers operations (the dining room may be evaluated at a future date). 3. Establish two (2) PSU Capstone teams to evaluate dining operations within the Inn: a. Team 1: Kitchen Operations Team (considering challenges from serving 2 dining areas, Whiskers and the NLI Dining Room). b. Team 2: Whiskers Operations Team 4. Teams 1&2 will conduct their studies at the same time to ensure operational conditions and variables are consistent for time periods being evaluated. 5. Historical POS data is available for evaluation but operational improvements have been made over the last 2-3 years invalidating the accuracy of some of this data (real-time data to be used to ensure current challenges are reflected in these studies). 6. Sponsor contacts for Team 1 (Kitchen Operations) will be Marissa, for Team 2 (Whiskers Operations) will be Sean. 7. Project goals for Teams 1 & 2 will be to improve Kitchen and Whiskers operations productivity and service levels leading to improved customer dining experiences (establishing operations KPIs could also be one of the project goals). 8. Teams 1 & 2 will provide initial project proposals, timelines, weekly updates, interim and final reports to their contacts and sponsors, see this link for details: a. http://www.lf.psu.edu/assets/docs/how-to-sponsor-learning-factory-engineering-penn-state.pdf

Requested Dept.: Industrial

Requirements: none


PSU Nittany Lion Inn 2

Contact: Thomas Neely

Address: Nittany Lion Inn, University Park, PA 16802

Project Title: Whiskers Operations Improvement

Description: 1. Food preparation and service challenges exist as a result of serving 2 different dining formats (i.e. menus) from one kitchen. 2. Initial focus will be Kitchen and Whiskers operations (the dining room may be evaluated at a future date). 3. Establish two (2) PSU Capstone teams to evaluate dining operations within the Inn: a. Team 1: Kitchen Operations Team (considering challenges from serving 2 dining areas, Whiskers and the NLI Dining Room). b. Team 2: Whiskers Operations Team 4. Teams 1&2 will conduct their studies at the same time to ensure operational conditions and variables are consistent for time periods being evaluated. 5. Historical POS data is available for evaluation but operational improvements have been made over the last 2-3 years invalidating the accuracy of some of this data (real-time data to be used to ensure current challenges are reflected in these studies). 6. Sponsor contacts for Team 1 (Kitchen Operations) will be Marissa, for Team 2 (Whiskers Operations) will be Sean. 7. Project goals for Teams 1 & 2 will be to improve Kitchen and Whiskers operations productivity and service levels leading to improved customer dining experiences (establishing operations KPIs could also be one of the project goals). 8. Teams 1 & 2 will provide initial project proposals, timelines, weekly updates, interim and final reports to their contacts and sponsors, see this link for details: a. http://www.lf.psu.edu/assets/docs/how-to-sponsor-learning-factory-engineering-penn-state.pdf

Requested Dept.: Industrial

Requirements: none


PSU Office of Research Information Systems

Contact: Jim Taylor

Address: 105, The 330 Building, University Park, PA 16801

Project Title: Analyze System Email Notifications from Research Administration Sytems

Description: System Email Notifications: All research administration systems send notification to faculty regarding activity related to their research – proposal submission, award status, approvals received, etc. This has resulted in researchers receiving a very large volume of emails, which rather than improving communication with faculty, has diminished it. The goal of this project would be to analyze our use of email notifications, identify the most essential ones and recommend which notifications to add, change or eliminate.

Requested Dept.: EDG

Requirements: none


PSU Origami Engineering

Contact: Paris vonLockette

Address: 160 Hammond Bdlg, University Park, PA 16803

Project Title: Origami Engineering: Automation of a 3D printing platform using Labview

Description: Note that this project requires students with knowledge of or willing to learn Labview. The OE team at PSU is developing a multi-pool DLP 3D printing system for printing with magnetic resins. The current system consists of aluminum framing, rail guides , and slides with functional( but manual) x, y, and z axis translation of the multi-pool system; a large, iron E-core inductor and magnet wire for winding an electromagnet; and Form 1 compatible resin pools. The goal of the project is to advance the 3D printing system beyond its current state by adding controlled stepper motors to the frame for automation and adding control of the completed electromagnet. Control of both subsystems would come from a central controller, a PC running Labview. The team would have access to all existing equipment stated above. Additional equipment, including stepper motors, a programmable power supply, and printing materials for testing would be purchased by the team. The objectives for the team are to 1. Design a Labview VI capable of positioning four separate stepper motors based on user inputs; 2. Include in the Labview VI the ability to control a programmable power supply in a fashion integrated with the above positioning; 3. Implement the electromagnet subsystem into the printer by finalizing its machining(most likely outsourced), completing its winding, and operating it with the programmable power supply via a LabView VI; 4. Design, select, purchase, and physically integrate into the printer three stepper motors for xyz-axes translations; 5. Design, select, purchase and physically integrate into the printer one additional stepper motor for a-axis rotation; 6. Link the LabView VI to the 4 stepper motors for control of x-y-z-a axes positioning. 7. Complete a final demonstration and provide documentation Students will be able to speak regularly with past students who designed and fabricated the translation stages of the frame. Note that for item 5 the team will work closely with the student currently finalizing the a-axis design.

Requested Dept.: Electrical, Mechanical

Requirements: none


PSU PennTAP

Contact: Tanna Pugh

Address: The 329 Building, Suite 222, University Park, PA 16802

Project Title: Real-time On-Site Energy Assessment Report Generation

Description: Background PennTAP helps Pennsylvania companies improve their competitiveness by providing technical assistance and information that addresses three main areas: Energy and Environment, Information Technology, and Innovation. The program focuses on helping smaller firms that normally do not have the in-house expertise or resources to resolve specific technology questions or needs. Operated by Penn State Outreach, PennTAP offers technical assistance for Pennsylvania manufacturers to reduce pollution while decreasing greenhouse gas (GHG) emissions and improving energy efficiency; provides information system support; and coordinates innovation and new product development services. Technical advisors on PennTAP’s Energy Team work with small to midsized manufacturers to provide no-cost facility assessments to improve energy efficiency and reduce GHG emissions which result in reduced operating costs. Common assessment areas include compressed air, lighting systems, HVAC, boilers, process ovens, and other manufacturing processes. Project Objective The objective of this project is to develop a consolidated software tool to allow for the efficient creation of client reports. PennTAP’s goal is to tailor the tool for a tablet, such as a Microsoft Surface or an Apple iPad, that can be easily carried to record the data collected at the client site. The tool would automatically process the data entered on site to calculate the energy saving opportunities and generate a draft report for the company. The draft report would be available for discussion with the client at the end of the site visit. Targeted assessments will likely include lighting upgrades, compressed air systems, and boilers. PennTAP will provide students with the calculations and descriptions of all the energy saving opportunities; the team, however, will be required to understand and possibly augment the calculations. The proposed calculations may need to be refined or expanded to include additional input variables. Deliverables The final deliverable will be a software tool (utilizing Excel, Word, or other programs) for each targeted energy area (e.g., lighting, compressed air, and others as applicable). The submitted software tool will be in working form with clear instructions for use. Expectation of Team Team members are expected to attend at least two energy assessments. The first assessment will be to provide the team with context related to the project. The second assessment will provide an opportunity to evaluate the tool(s) and make improvements or changes before submitting the final project. Team members may be from any engineering discipline, but suggested team members are those with an energy, industrial, computer, and chemical (process) engineering focus.

Requested Dept.: CompSci, CSE, Energy, Mechanical

Requirements: none


PSU Psychology

Contact: Alicia Grandey

Address: Moore Building, PSU, University Park, PA 16802

Project Title: Design and implementation of automated TA assignment system

Description: Psychology has one of the largest graduate programs at PSU, and its magnitude creates many challenges, particularly when it comes to assigning graduate students to teaching assistantships (TAs). Twice a year, the Director of Graduate Training (DGT) spends countless hours matching graduate students to around 1300 hours of teaching assistantships in the weeks just prior to the new semester. This process is manual, time-consuming, and labor-intensive, and TA assignments undergo numerous iterations as faculty members’ and students’ preferences, schedules, and availability change. The goal in this capstone design project is to design, implement, and test an automated and user-friendly method for matching graduate students to TA slots based on multiple, and often conflicting, criteria. The capstone team will meet with the DGT, leaders of the psychology faculty, and current TAs to define specific criteria, constraints, and preferences for the problem. The team will then identify suitable platforms for implementation and develop a system prototype. The system should gather the necessary information, make TA assignments, and then report results in a user-friendly format. The system will then be tested and evaluated in collaboration with the DGT using TA assignments from a previous semester. After demonstration and testing, the system should be refined and updated accordingly and readied for deployment in August 2017. Project deliverables include all of the source code, algorithms, surveys, and/or software necessary to implement the system along with detailed system documentation. Finally, the team should also deliver a concise user manual that clearly defines how faculty, students, and the DGT use the system.

Requested Dept.: Industrial

Requirements: none


PSU QuantDev/StudioLab

Contact: Nilam Ram

Address: 407 Biobehavioral Health Building, University Park, PA 16802

Project Title: 3-D Printing of Acoustic Bowls

Description: 3-D printing simultaneously extends the possibilities for data visualization and sonification. Digital fabrication processes allow for printing of custom-designed objects with special properties. The goal of this project is to 3-D print a set of “ceramic bowls” that have both unique shape and acoustic properties. (1) Bowl Acoustics. When struck with a drum mallet many bowls produce resonant sounds, ringing with particular tones and for specific duration. Advances in printing with mixed materials may further allow that different sections of the same bowl may resonate in different ways. Like steel-pan drums (https://en.wikipedia.org/wiki/Steelpan) often used in reggae music, different portions of the inner surface of the bowl might thus be tuned for different resonances. (2) Bowl Shape. Curvature and depth of bowls can be represented as a set of radial basis mathematical functions, the parameters of which can be driven by empirical data (e.g., http://www.redcedartech.com/docs/HEEDSMDO/Technical_Reference/Kriging_and_RBF_Response_Surfaces.htm). In the same way that 2-d graphs are used to “visualize” data, 3-D bowls provide new opportunity to “materialize” data (e.g., create data sculpture). Project Objective: Design and 3-D print a set of acoustic bowls that have different acoustic properties and whose shape is defined by an empirical data stream provided by the sponsor. The bowls should be relatively lightweight (transportable) and suitable for (a) display in both technical and sci-art gallery settings and (b) use in live musical performance. Project Deliverables: 1. A description of how the bowls embody the empirical data and invoke acoustic resonance. 2. Detailed design documentations of the 3-D printing production process. 3. Software code developed. 4. Prototype bowls and a demonstration of their functionality.

Requested Dept.: EDG, ESM, MatSci, Mechanical

Requirements: none

3-D Printing of Acoustic Bowls


PSU RERC on AAC 1

Contact: David McNaughton

Address: 227 CEDAR Building, University Park, Pe 16802

Project Title: Using Speech Recognition to Control the Home Environment

Description: The speech recognition feature of Generic Home Technology (GHT) such as Amazon Echo and Google Home provides the capability to use speech to help control the home environment. These GHT devices hold significant promise for persons with severe physical disabilities both in activities that require physical skill but have now been mechanized (e.g., opening doors), and also in activities that require literacy skills (e.g., programming a thermostat, using a smartphone app). These GHT devices also are less expensive and more widely available than specially designed assistive devices with features “dedicated” to providing environmental control for people with disabilities. This project addresses the needs of individuals with communication disabilities who use a speech generating device (SGD) to communicate, and those with significant speech impairments who rely on their speech (even though they may be difficult to understand). For these persons, the SGD (or their natural speech) may provide a familiar way to control their environment using GHT. However, while GHT holds the promise of providing environmental control, the extent to which GHTs will respond to the speech output of SGDs, require modifications to interface the two devices (SGD and GHT), or “understand” less intelligible speech is unknown. The student team will partner with an individual with a severe physical disability who uses a speech generating device, and work to (a) identify currently unmet needs in controlling the home environment ( e.g., opening doors, closing curtains) (b) evaluate usefulness of GHT in addressing these needs (c) implement hardware and software changes ( e.g., programming of SGD, working with API for Amazon Alexa) to address needs (d) evaluate impact of modifications Deliverables include (a) report on needed home modifications and usefulness of GHT in addressing these needs (b) proposal submitted to RESNA student Design Competition, including written proposal and video http://aac-rerc.psu.edu/wordpressmu/RESNA-SDC/

Requested Dept.: CompSci, CSE, ESM

Requirements: none


PSU RERC on AAC 2

Contact: David McNaughton

Address: 227 CEDAR Building, University Park, Pe 16802

Project Title: The use of head-tracking and eye-tracking in challenging populations with the Intel RealSense RS300

Description: The use of head- and eye-tracking technology holds promise as a method of computer access for many individuals, but for some individuals with disabilities it is difficult to use this technology to control a cursor. The Intel RealSense RS300 may provide a low cost and effective method of head- and eye-tracking for individuals who have been unable to use eye-tracking technology in the past. The challenge for this team will be to assess the accuracy of the Intel RealSense RS300 as a method for head- and eye-tracking using information (e.g., head and eye movement plus facial markers) captured by the Intel RealSense RS300. The team will also be asked to investigate ways in which coordinated used of head- and eye-tracking information may provide better control of the cursor, as well as the usefulness of other facial movements ( e.g., blinking, smiling) as a method of computer input. We will be able to provide this team with a Surface tablet computer, the Intel RealSense RS300 camera, and the the Intel RealSense developers kit. This team will also partner with Tom Jakobs and Ethan Williams at Invotek, a national leader in innovative engineering solutions for persons with severe physical disabilities (https://www.invotek.org/) It is expected that students will develop a working prototype that advances our understanding of the coordinated use of head- and eye-tracking technology for persons with disabilities. Students will also be expected to submit their finished work to the Rehabilitation Engineering and Assistive Technology Society of North America (RESNA) Student Design Competition (more information at http://aac-rerc.psu.edu/wordpressmu/RESNA-SDC/ ).

Requested Dept.: Bio, CompSci, CSE, ESM

Requirements: none


PSU RERC on AAC 3

Contact: David McNaughton

Address: 227 CEDAR Building, University Park, Pe 16802

Project Title: ChatBot technology to support the acquisition of Active Listening Skills

Description: Professionals who will work with families need to demonstrate strong communication skills, including the use of Active Listening skills (http://aac.psu.edu/wp-content/uploads/2015/11/Vostal-et-al.-2015_LAFF_Corr.pdf ) . While these skills can be practiced in role plays, it would be useful to determine if ChatBot technology could be developed to play the role of the communication partner (e.g., parent of a child with a disability). That is, can a ChatBot be created that would play the role of the parent, and answer questions from the pre-service professional in a chat environment. Ideally the Chatbot could handle a 3-5 minute conversation in which a parent has a concern, and the teacher practices (1) greeting the parent, (2) asking questions to find out more about the concern (3) summarizing the parent's concern (4) suggesting a first step. At these times, the Chatbot should generate appropriate responses. A project to look at preparing teachers to interview victims of bullying can be seen at https://ed.psu.edu/virtualroleplay/technology-design-development and may provide insight into one possible technical approach. I can also share videotapes of role-play interactions so that the student team can obtain information on typical interactions between pre-service SLPs and parents. It would also be desirable for the Chatbot ( or additional software) to analyze and provide information on the characteristics of the conversation. For example, how many questions were asked by the professional? Did the professional provide a summary? Check for the acceptability of the summary? It is expected that students will develop a working prototype that advances our understanding of the use of Chatbots to build interview skills in working with parents of children with disabilities. Students will also be expected to submit their finished work to the Rehabilitation Engineering and Assistive Technology Society of North America (RESNA) Student Design Competition (more information at http://aac-rerc.psu.edu/wordpressmu/RESNA-SDC/ ).

Requested Dept.: CompSci, CSE, ESM

Requirements: none


PSU START Lab

Contact: Reid Berdanier

Address: 3127 Research Dr., State College, PA 16801

Project Title: A compact thermocouple connector solution for gas turbine engine component testing

Description: Thermocouples are a standard method for measuring temperatures in experimental tests. Ongoing research at Penn State University’s Steady Thermal Aero Research Turbine (START) Lab implements thermocouples to accurately monitor temperatures for performance calculations. Currently, thermocouple connectors are available in “standard” or “miniature” styles from many manufacturers. However, space constraints for new project goals in START facilities require a new compact solution to connect many thermocouple wires. This project will design and build a custom prototype connector solution that fits the following project needs: (1) Space limitations (to be defined) (2) Temperature requirements in excess of 250F (i.e., material selection) (3) Continuity of thermocouple materials for accuracy measurements (e.g., E-type, T-type, K-type) (4) Capability to connect small-gage wires (~38 AWG) to larger gage wires (~24 AWG) across the connector It is expected that 3D printing technologies will be an ideal avenue through which to accomplish this goal. A successful outcome from this design effort will support high-accuracy efficiency measurements benefiting technology advancement for aircraft engines and land-based energy production.

Requested Dept.: Mechanical

Requirements: none


PSU Sustainable Housing Initiative

Contact: Nathaniel Belcher and Rohini Raghavan

Address: 121 Stuckeman Family Building, Penn State, University Park, PA 16802

Project Title: Housing Taxonomy Database

Description: HOUSING TAXONOMY DATABASE AND VISUALIZATION Sponsor: Sustainable Housing Initiative Research Group INTENT: The housing industry in the United States is highly fragmented in nature, and there is a clear need for a comprehensive platform that aggregates data from housing projects across the country and provides a ‘bird’s-eye view’ of the sector. The primary goal of this research would be to compile the database behind this platform by classifying production housing* projects on the basis of 23 key building ‘attributes’ - ranging from the date of construction to the type of building systems (see appendix) - through which the current state and future direction of the housing industry can be better understood. This database would be used to develop a web visualization platform (that will be hosted on the SHI’s website) which will integrate multiple ‘filters’ to turn on/off specific attributes and assist professionals - from academics to researchers and from architects to builders - in making smarter housing-related decisions in the future. * A Production Home Builder builds residential properties on land owned by the building firm (this excludes custom-designed homes) DELIVERABLES: Develop a database of single-family, duplex, multifamily (mixed-use included) and institutional (residence halls etc.) production housing projects using the uniform classification scheme (see appendix) and integrate this database into a proof-of-concept web visualization platform. THE SUSTAINABLE HOUSING INITIATIVE: The SHI was formed in 2012 at the Penn State as a response to environmental challenges in the residential sector and to discuss the potential for a game changing initiative in the areas of housing and sustainability. The SHI working group consists of members with a diverse range of research expertise – from building science and design to community behavior and materials research - and builds off of past Penn State successes, including the 2007 and 2009 Penn State Solar Decathlon Homes, the Union County Energy Efficient Housing Program projects, and the GridStar Smart Grid Experience Center modular home at the Philadelphia Navy Yard.

Requested Dept.: CompSci, Energy, EDG, ESM, Electrical, MatSci, Mechanical

Requirements: Intellectual


PTC Inc.

Contact: Jeff Bacher

Address: 350 Eagleview Blvd Suite 200, Exton, PA 19341

Project Title: The Internet of Things and Crisis Management Phase II

Description: ThingWorx is the first software platform designed to build and run the applications of the connected world. ThingWorx reduces the time, cost, and risk required to build innovative Machine-to-Machine (M2M) and Internet of Things (IoT) applications. As the leading IoT platform it is very important for us as a company to continue to find new and innovative ways to use the Internet of Things to solve real world problems. For this new ThingWorx Learning Factory project we are looking for a group of creative Computer Science students to assist us with a project that will utilize a variety of different types of IoT devices including smart phones, sensors, alarms, etc. and the ThingWorx platform to expand upon an initial campus safety solution. Specifically, we are imagining an application that will aggregate real-time data reported by students and devices, analyze that data, and enable the immediate communication of important safety information to the entire campus. Primary Goals • Collaborate with our team and expand the list of possible campus safety situations that could be improved with ThingWorx and IoT technologies • Choose the best solutions and design an implementation on the ThingWorx platform that will leverage the selected IoT technologies including improving on a smartphone app prototype to ingest data related to campus safety scenarios • Implement a proof-of-concept solution using the ThingWorx platform and examples of selected IoT technologies Secondary Goals • Expand proof-of-concept to include feedback of analyzed data to sensors, devices, and/or people, for example directing students away from campus safety issues Hardware may be purchased using the project budget to support the physical/visual demo that will be displayed at the Senior Design Showcase. "

Requested Dept.: CompSci, CSE

Requirements: Confidential, Intellectual


Quaker Chemical Corporation

Contact: Dr Robert Evans

Address: 901 Hector Street, Conshohocken , PA 19428

Project Title: Machining of Automotive Cast Aluminum Alloys

Description: Effects of Material Property and Microstructure on Fluid Performance in the Drilling and Reaming of Cast Aluminum Alloys Hypoeutectic Al-Si-Mg cast alloys are utilized in the production of many industrial components, including automotive engine blocks and cylinder heads. In the assessment of the performance of lubricating fluids for potential use in the machining of this alloy, it is necessary to conduct controlled machining tests whereby the ability of the fluid to minimize cutting forces and tool wear in drilling as well as to produce smooth surface finish in reaming, are measured. In the machining of cast aluminum alloys it is known that variations in alloy composition and resultant microstructure and material properties, can lead to significant differences in machinability of the metal. For this reason, a study of the microstructure and properties of three cast aluminum alloys commonly used in automotive engine production, as well as their relative machinability in drilling and reaming operations, will provide valuable information regarding the machining challenges presented by these metals, and also the lubrication requirements needed from the metalworking fluid used. What will be required: Using three different cast aluminum alloys, Al 356-T6, Al 319-T6, and Al 380, 1. Determine mechanical properties (hardness, UTS etc.) of the three alloys to determine differences 2. Measure the microstructural features of the three alloys. 3. Using two different metalworking coolants, conduct drilling and tests to measure the performance of the two fluids and to determine the machinability differences which exist between the three alloys. 4. Attempt to correlate mechanical property and microstructural differences to any machinability differences observed.

Requested Dept.: Industrial, MatSci

Requirements: Intellectual


Rain Reality LLC

Contact: Elaine Demopolis, Ria Bhatia

Address: 430 W Beaver Ave APT 1, State College, PA 16801

Project Title: Augmented Reality Campus Tour

Description: Overview The highly popular game Pokémon Go has introduced the mass public to the experience of Augmented Reality (AR). AR, by definition, overlays virtual objects over the real world to introduce virtual information. It is expected that the global AR market will reach over $100 billion by 2024. This project will allow capstone students to build an app that leverages AR for the purpose to teach Penn State visitors and new students about specific locations on campus. The capstone students may choose content that they find useful and interesting (i.e. important spots for prospective students, freshmen students, different majors/interests, etc.). AR has exploded into the phones of millions of Pokémon Go users and has been introduced across many ages and demographics. But the question remains, how can AR be useful? Specifically, how can AR be integrated into applications as an educational tool? This project will challenge you to think about how to design an AR app with an educational purpose. At your university - Penn State University Park - you will explore how people new to the Penn State campus can learn about the university's hotspots and centers using an interactive, engaging location-based (LBS) app. Your first steps should be to perform a customer discovery phase to determine which users your app will target and therefore what range of content to prepare. Goals Objective: To build a location-based (LBS) iOS/Android app that features a Pokémon Go-like experience where the user is dropped on to a Penn State map that hews to the real world and enables the user to learn more about specific locations on Penn State's campus through AR. Key deliverables: 1. Track the GPS location of the user and integrate with in-app map 2. Determine when AR content is enabled (distance of user from location, image recognition, etc.) 3. Compile and add AR content for specific locations* *AR content can include historical information, links to websites, 2D/3D objects, etc. as long as virtual content shows in real world first. People & Roles App Development Lead: Leads the development of the Android or iOS application using Unity workflow AR Development Lead: Leads the development of the AR feature Project Manager: Leads the communication between the team and Elaine and Ria. Understands class deadlines and keeps the team on-track to meet project goals. Content Expert: Gathers content for the application from around campus. Designs how user's will go through the application and learn the content. Context Use Cases Users want to: 1. See pop-up content for specific location when outside/inside location (i.e. determine how near user should be to location to activate content) 2. See on the in-app map where they are located in respect to the locations of interest Assumptions 1. User has either Android or iOS platform and is proficient in his/her platform navigation Proposal User Experience User shall use your app to learn more about locations they travel to on the Penn State University Park campus. When they walk around campus, they can track their location on the in-app map and see what locations they can travel to. When they reach a location, content will be activated through Augmented Reality when they hold up their phone to the place, from information blurbs to 3D models. User may even be able to hold up their camera to trigger image recognition for special content. Technical Aspects 1. Use Unity Personal version 5.5.0: https://store.unity.com/download?ref=personal 2. Depending on the expertise within your team develop for iOS or Android and use Unity to build to those platforms. 3. Use the Unity Asset Store to purchase 2D and 3D models. 4. Test the application regularly by deploying to an iPhone or Android device. Tasks and Timeline 1. Meet with Elaine and Ria on a weekly basis and update them on progress 2. Prepare development prototypes for every 6 weeks 3. After first meeting, within a week set up a plan for the semester to complete all deliverables listed above (make a calendar and send us link). Plan should include: class due dates, weekly meetings, prototypes, and timeline estimates for deliverables 4. Regularly test the application among yourselves and have 1-2 user tests Example tasks in chronological order 1. Deploy a dummy app from Unity to a smart phone 2. Perform user analysis and brainstorm content specific to users 3. Design the functionality of the application & gather content for AR (links, information blurbs) 4. Enable GPS tracking of cell phone and sync to an in-app map (think of how Pokemon Go does it) 5. Make design decisions for how AR content will be enabled at locations (i.e. solely through LBS or expand to image recognition) 6. Build the application to work with one location and do user testing to make sure assumptions are validated 7. Add more locations and associated AR content - if have time, add more AR capabilities like 3D models and cool UI design elements

Requested Dept.: CompSci, CSE, Electrical

Requirements: Intellectual


SCA Americas 1

Contact: Vanessa Gaboleiro

Address: 2929 Arch Street, Suite 2600, Philadelphia, PA 19104

Project Title: The SCA Consumer Challenge

Description: Can you come up with a new and innovative way to recruit, educate and retain consumers to the SCA baby brand? How to take part To be considered for 1st place you must meet all of the below criteria To create a team profile use the unique link www.scauniversitychallenge.com, then use this to upload your required challenge submission You must have a video describing your solution to the problem (2-3 min) – If you are unsure how to create a video please use https://www.powtoon.com/ You also have the option to create a WIX website presenting your concept, http://www.wix.com/ Further rules and stipulations will be found on the host site. To apply go here: www.scauniversitychallenge.com

Requested Dept.: EDG

Requirements: Confidential, Intellectual


SCA Americas 2

Contact: Vanessa Gaboleiro

Address: 2929 Arch Street, Suite 2600, Philadelphia, PA 19104

Project Title: The SCA Engineering Challenge

Description: The SCA Challenge problem (entrants must consider all three criteria): What type of packaging construction/solution would you consider a great diaper pack (and not just a plastic wrap that covers/protect the diapers in shelf and until you get them home)? What type of construction would make the pack simple and easy to handle and use (carry, open, getting products out, store etc.)? What type of packaging solution would you see additional value in from a user/usability perspective? How to take part • To create a team profile use the unique link www.scauniversitychallenge.com, then use this to upload your required challenge submission • You must have a video describing your solution to the problem (2-3 min) – If you are unsure how to create a video please use https://www.powtoon.com/ • You also have the option to create a WIX website presenting your concept, http://www.wix.com/ Further rules and stipulations will be found on the host site. To apply go here: www.scauniversitychallenge.com

Requested Dept.: EDG, Industrial

Requirements: Confidential, Intellectual


Scientific Systems, Inc.

Contact: Kent Vonada

Address: 349 Science Park Road, State College, PA 16803

Project Title: Production Test Modernization/Improvement

Description: Industrial Engineer Project - Penn State Learning Factory Scientific Systems, Inc. Description: Scientific Systems, Inc. (SSI) is a traditional job shop manufacturing operation employing 55 people and using linear production lines. Production currently has some function specific work cells that build common components for the top level pump assemblies. Every pump manufactured must be tested for compliance to either an internal specification or a customer supplied specification. All test data from the current test stands are recorded into a test database for proof of compliance and future reference for our Service Technicians. To accomplish this, SSI has designed test stands which test each pump to a pump specific “recipe”. These test stands currently reside in a single test cell and have become the bottleneck in our process when customer orders are extremely high. Our ultimate goal is to have identical manufacturing cells that can manufacture and test any product that we receive from our customers. To accomplish this, we must have additional test stands that are user friendly, accurate, robust and easily maintained for preventative maintenance purposes. Our current test stands are satisfactory but not ideal. In our future manufacturing environment we will be pursuing cross-training of all team members so we have ultimate flexibility within a cell. Ideally, the ultimate test stand would be intelligent enough to recognize the pump type, select the correct “recipe”, display the required next step in an easy to read and follow format that allows less technical team members to perform the tests. Scope and Deliverables: •Improve productivity by performing evaluations of current test stands, identify opportunities to improve the test stands/programs, propose changes to test stands to make them more user friendly for less technical personnel, build and demonstrate the test stand of the future. To include integration of test stand data into a database that allows archiving, printing of a test data sheet to ship with product, review past results if a pump is returned for repair/upgrade, etc. •Cost proposal and Bills of Material for test stands. •Process documentation to accompany new test stands. •Build test stands that can be used in our current production environment. NOTE: After evaluation of current test stands it is possible the team may not be able to optimize the design beyond our current design. In this event, assisting in the building of additional test stands would be extremely beneficial to SSI. • Study and suggest optimized plant layout for all-inclusive production and test cells. • Review current material staging areas for inclusion into the cells utilizing a pull verses push logic. Requirements: Applicants should be Industrial/Mechanical/Electrical Engineering majors, with ability to analyze, document, and design using all current software and technologies. They should have the ability to work independently with minimal supervision.

Requested Dept.: Industrial

Requirements: none


Shanghai ZJ Bio-Pharma Co.,Ltd.

Contact: Walter Zhang

Address: No.15 Building, No.188 Xinjunhuan Road, Shanghai,China, Ch 20111

Project Title: Automated Sample Preparation of Microbial Genome Nextera for High-throughput Sequencing - GLOBAL

Description: GLOBAL PROJECT WITH SJTU: Automated Sample Preparation of Microbial Genome Nextera for High-throughput Sequencing --Sequencing Quality Control 16s rDNA Real Time PCR Kit [Project Objective] To develop a real time PCR kit which can be used to detect the high-throughput sequencing samples and the concentration. [Project Background] With the more and more widely application of the high-throughput sequencing technology in precision medical like noninvasive screening, tumor diagnosis and treatment, human microorganism and health, molecular breeding and even various basic research fields, reliable, stable and high quality nucleic acid extraction and sequencing library preparation has a direct impact on the quality of the sequencing data. Automated library construction is conducive to the output of the stable, reliable and high quality sequencing library with high volume, high throughput and significant time saving, which can avoid the problems such as experimental deviation caused by manual operation. Shanghai ZJ Bio-Tech Co., Ltd plans to develop APP for the preset NGS library based on the high-throughput automated nucleic acid extraction workstation, NGS Clean-up and Size Select kit (beads) and multi-functional (including fluorescence quantitative, capillary electrophoresis) automated library quality control, to optimize the parameters of sample processing, library construction and library quality control, to test and evaluate the performance indicators in order to successfully build a stable and high flux "automated sample preparation system for microbial genome Nextera high-throughput sequencing". The automatic monitoring of sequencing library is an organic component of this automated sample preparation system. Sequencing has strict requirements on the sequencing library concentration. If the concentration of the sequencing library is too low, sequencing data volume will be low, which is not conducive to the subsequent bioinformatics analysis or cannot accurately reflect the genetic information of the real sample; if the concentration of the sequencing library is too high, the density of the sequencing chip cluster will be dense, bursting the chip to result the failure of the experiment. Meanwhile, the quality control requires similar library concentration before pooling, to ensure the final data amount from each sample is almost the same; and once sequencing start up, because the sequencing reagents are one-time expensive consumables, it will immediately produce a high reagent consumption cost. Therefore, in order to reduce the sequencing risk, to ensure obtain the high quality data, before run the library on the machine, the laboratory operating procedures will require to detect and ensure that the library concentration reach the standards. [Project Content] Abstract: High-throughput sequencing, as a target gene sequencing technology applied to the study of microbial colony diversity in the environment, identifies sample microbial colony members, analyzes and compares multiple microbial colony structure by PCR amplification sequencing covering one or more continuous variable region of 16s rDNA. In general, sequencing samples first need nucleic acid extraction and purification, library construction and purification, quality control, and then for sequencing. Sequencing samples across different species, with tremendous difference. Reagent to be developed for the detection of nucleic acid and gene library concentration is a single reagent, and is suitable for different sample types. 16s rDNA is a gene encoding prokaryotes ribosome small subunit, 1542bp in length. Its molecular size is moderate, mutation rate is small, and it is the most common and useful marker of bacterial systematics study. 16s rDNA gene sequence covers 9 variable regions and 10 conserved regions. The sequence of conserved region reflects the relationship among species, and the sequence of variable region can reflect the difference of species. 16s rDNA amplicon sequencing usually select 1~2 high variable regions and use conserved region to design universal primer for PCR amplification, then carry out the sequencing analysis and species identification of the high variable regions. 16s rDNA amplicon sequencing technology has become an important means to study the composition and structure of microbial communities in environmental samples and , dig into the relationship between samples. 16s rDNA sequencing now can use a variety of different sequencing instruments for sequencing, including Roche 454, Illumina MiSeq, Life PGM or Pacbio RSII three generation sequencing instrument. Different instruments have their advantages and disadvantages. At present, the most popular is Illumina MiSeq, because it is most balanced in flux, length and price. The third generation sequencing from Pacbio can do a full length sequencing of 16s rDNA with good analysis result, but the cost is high and price is expensive, while the specificity of V3-V4 area applied to MiSeq platform is good and the database information is full, so now it is widely used. We develop a 16SrRNA gene Real Time PCR kit for 16s rDNA V3-V4 area, which can control the sample loading quantity quickly and conveniently, to make the sequencing data more secure. Project main components: The project mainly includes 16SrRNA Real Time PCR Kit design and development planning, primer and probe design and synthesis, performance evaluation, stability evaluation, experimental production and performance evaluation, pilot production and quality control, registration test and other parts. See the following: (1) Planning on Design and Development of 16SrRNA Real Time PCR Kit The main work is to collect and arrange the reagent planning data, such as demand analysis, market scale, application scope, team work division, project specific design, and project schedule and so on. (2) Design and Development of 16SrRNA Real Time PCR Kit Product design and development mainly includes research on the main raw materials (including the design and synthesis of 16sDNA primer and probe, synthesis of positive control, preparation of internal control plasmid and etc), reaction system debugging, sample processing and comparison of nucleic acid extraction, study on positive judgment value and etc. (3) Performance Evaluation of 16SrRNA Real Time PCR Kit The item mainly includes the evaluation of analytical sensitivity, analytical specificity, precision, anti jamming capability and etc. (4) Stability Evaluation of 16SrRNA Real Time PCR Kit The item mainly includes the evaluation of accelerated stability, transport stability, real-time stability and etc. (5) Experimental Production and Performance Evaluation The item mainly includes the confirmation of the experimental production formula, the trail packaging label sample and storage condition, the tidying of the laboratory equipments and process flow diagram, sample inspection, product manual writing and etc. The performance evaluation method in this item is basically identical with point (4). (6) Pilot Production and Quality Control The item mainly includes pilot production and quality control, completed by the production department and QC department, assisted by developers. (7) Registration Test The item mainly includes spot check on the sampling batch, registration test, clinical trials, registration data preparation, and so on, completed by the registration group and clinical group, assisted by developers. [Project Deliverables] Product: Bacteria 16SrRNA Real Time PCR Kit; matched nucleic acid extraction kit; common sample processing method and etc.

Requested Dept.: Bio

Requirements: Confidential, Intellectual


Shell 1

Contact: Ryan Moyer

Address: 12880 Route 6, Wellsboro, PA 16901

Project Title: Shell Eco-Marathon - Team 1 (New Design)

Description: For over 30 years, Shell Eco-Marathon competitions have challenged future automotive engineers and scientists to push the limits of energy efficiency and innovate solutions to the world’s mobility challenges. Now, more than 1,000 high school and college students from across the Americas will head to Detroit to see who can design and build ultra-energy efficient vehicles and go the furthest using the least amount of energy in Shell Eco-marathon Americas 2017. Penn State students in this project will have the opportunity to travel to Detroit and participate in he 11th annual competition, April 28-30, 2017. Covering more than half a million square feet, inside Cobo Center event-goers will explore a multi-sensory journey into the world’s energy future and see what the student teams are doing behind the scenes of the competition. More information on this year's Eco-marathon can be found on the website: http://www.shell.com/energy-and-innovation/shell-ecomarathon/americas.html Penn State traditionally enters two cars into the competition. The Urban Concept Car is currently constructed with a compressed natural gas (CNG) engine. This semester's team will be expected to tune the engine to get the best gas-mileage possible and work on the automated-controls system of the car. Test-driving the car to optimize fuel economy before the competition is expected. The Prototype Car is currently constructed with a battery electric propulsion. This semester’s team will be challenged with building/tuning the motor controller and new car frame. Students will also be encouraged to research and develop new car designs that maximize fuel-efficiency for future Eco-Marathon competitions. A video of last year's Penn State team can be found here: https://www.youtube.com/watch?v=4jWbbOQQlTk

Requested Dept.: Chem, Energy, EDG, ESM, Electrical, Mechanical

Requirements: none

Shell Eco-Marathon  - Team 1 (New Design)


Shell 2

Contact: Ryan Moyer

Address: 12880 Route 6, Wellsboro, PA 16901

Project Title: Shell Eco-Marathon - Team 2 (Prototype)

Description: For over 30 years, Shell Eco-Marathon competitions have challenged future automotive engineers and scientists to push the limits of energy efficiency and innovate solutions to the world’s mobility challenges. Now, more than 1,000 high school and college students from across the Americas will head to Detroit to see who can design and build ultra-energy efficient vehicles and go the furthest using the least amount of energy in Shell Eco-marathon Americas 2017. Penn State students in this project will have the opportunity to travel to Detroit and participate in he 11th annual competition, April 28-30, 2017. Covering more than half a million square feet, inside Cobo Center event-goers will explore a multi-sensory journey into the world’s energy future and see what the student teams are doing behind the scenes of the competition. More information on this year's Eco-marathon can be found on the website: http://www.shell.com/energy-and-innovation/shell-ecomarathon/americas.html Penn State traditionally enters two cars into the competition. The Urban Concept Car is currently constructed with a compressed natural gas (CNG) engine. This semester's team will be expected to tune the engine to get the best gas-mileage possible and work on the automated-controls system of the car. Test-driving the car to optimize fuel economy before the competition is expected. The Prototype Car is currently constructed with a battery electric propulsion. This semester’s team will be challenged with building/tuning the motor controller and new car frame. Students will also be encouraged to research and develop new car designs that maximize fuel-efficiency for future Eco-Marathon competitions. A video of last year's Penn State team can be found here: https://www.youtube.com/watch?v=4jWbbOQQlTk

Requested Dept.: Chem, Energy, EDG, ESM, Electrical, Mechanical

Requirements: none

Shell Eco-Marathon  - Team 2 (Prototype)


Shell 3

Contact: Ryan Moyer

Address: 12880 Route 6, Wellsboro, PA 16901

Project Title: Shell Eco-Marathon - Team 3 (Urban)

Description: For over 30 years, Shell Eco-Marathon competitions have challenged future automotive engineers and scientists to push the limits of energy efficiency and innovate solutions to the world’s mobility challenges. Now, more than 1,000 high school and college students from across the Americas will head to Detroit to see who can design and build ultra-energy efficient vehicles and go the furthest using the least amount of energy in Shell Eco-marathon Americas 2017. Penn State students in this project will have the opportunity to travel to Detroit and participate in he 11th annual competition, April 28-30, 2017. Covering more than half a million square feet, inside Cobo Center event-goers will explore a multi-sensory journey into the world’s energy future and see what the student teams are doing behind the scenes of the competition. More information on this year's Eco-marathon can be found on the website: http://www.shell.com/energy-and-innovation/shell-ecomarathon/americas.html Penn State traditionally enters two cars into the competition. The Urban Concept Car is currently constructed with a compressed natural gas (CNG) engine. This semester's team will be expected to tune the engine to get the best gas-mileage possible and work on the automated-controls system of the car. Test-driving the car to optimize fuel economy before the competition is expected. The Prototype Car is currently constructed with a battery electric propulsion. This semester’s team will be challenged with building/tuning the motor controller and new car frame. Students will also be encouraged to research and develop new car designs that maximize fuel-efficiency for future Eco-Marathon competitions. A video of last year's Penn State team can be found here: https://www.youtube.com/watch?v=4jWbbOQQlTk

Requested Dept.: Chem, Energy, EDG, ESM, Electrical, Mechanical

Requirements: none

Shell Eco-Marathon  - Team 3 (Urban)


Siemens Industry Inc. 1

Contact: Ted Fowler, Bill Edinger, Jim Salerno

Address: 15375 Memorial Drive, Houston, TX 77079

Project Title: Design a Crude Oil Pump Station Functional Scale Model - Team 1

Description: Note: This project is mostly mechanical and electrical design with a little chemical engineering. EE, ME, ESM and students from EDSN 460W would be a good fit. Only need 1 CE for the fluid design. (thanks Tim!) The ‘Smart Pumping’ Projects ---------------------------- The Smart Pumping Projects are multiple semester (phase) development projects where designs and results from each semester are used by teams in future semesters to continue development. The first phase was executed by two Capstone Project teams in the spring of 2016 where the students designed a digital twin of a centrifugal pump, simulation and control software where the pump and a section of pipe. The second phase was executed in the fall of 2016 by two Capstone Project teams (see the cover sheet) whose crude oil pump station simulation and optimization design won them 1st place and the Engineering Design Showcase event. Phase 3 is the design of a functional scale model of a crude oil pump station and a section of pipeline. Phase 4 teams will use the Phase 3 design to construct (build) and test the scale model using PLC software developed by the Phase 1 and 2 teams. Phase 3 Project Description --------------------------- The project is to design a functional scale model of a crude oil tank farm, pump station and length of pipeline. The tank farm will have 3 “oil” storage tanks for low, medium and high viscosity liquids. The pump station will have 4 pumps, 4 motors and 4 variable speed drives. Students must formulate and provide mixing instructions for three different water based colored liquids to simulate low, medium and high viscosity oils. The “pipeline” must of sufficient length to put adequate load on the pumps. The project includes design a metal support structure (frame) and crating. The purpose of the model is to test batch change control and optimization algorithms and compare results to high-resolution simulation results. Siemens also plans to use the model as a demonstrator at industry trade show events in North America. Students are encouraged to validate hydraulic operation, performance and calculations (flow, pressure, water hammer, temperature rise etc.) using appropriate software. The electrical design must be compliant with the National Electric Code standards for control panels. The project teams may produce a 3D printed model of the pump station scale model however this is not a required deliverable for this project. Siemens Sponsoring Mentoring Representatives -------------------------------------------- Ted Fowler prepared the project description and will attend the kickoff event on January 17th 2017 with two Siemens colleagues, Bill Edinger and Jim Salerno (both Penn State Alumni). After the kickoff event Bill and Jim will assume and share the lead role as project sponsors and mentors, participate in weekly network meetings with the Capstone Project teams and attend the Engineering Design Showcase Event in April. Fowler will available to consult on a limited basis. Specifications and Deliverables ------------------------------- Preliminary project specifications are listed in drawing PSU-Prj3-2017-Spring-Specifications-001. Project deliverables are listed in drawing PSU-Prj3-2017-Spring-Deliverables-001. All project deliverables will be used by future Capstone Project teams to purchase equipment, build and test the scale model. Safety and Design ----------------- Designing for safety is paramount. Liquids under pressure escaping piping due to cracks or failed joints can cause bodily. Electrical safety is equally important, electrocution from equipment powered standard 120VAC outlets can result in death. Water and electrical equipment, , circuits and conductors must never meet. Frequent design reviews with respect to safety are required.

Requested Dept.: Chem, ESM, Electrical, Mechanical

Requirements: none


Siemens Industry Inc. 2

Contact: Ted Fowler, Bill Edinger, Jim Salerno

Address: 15375 Memorial Drive, Houston, TX 77079

Project Title: Design a Crude Oil Pump Station Functional Scale Model - Team 2

Description: Note: This project is mostly mechanical and electrical design with a little chemical engineering. EE, ME, ESM and students from EDSN 460W would be a good fit. Only need 1 CE for the fluid design. (thanks Tim!) The ‘Smart Pumping’ Projects ---------------------------- The Smart Pumping Projects are multiple semester (phase) development projects where designs and results from each semester are used by teams in future semesters to continue development. The first phase was executed by two Capstone Project teams in the spring of 2016 where the students designed a digital twin of a centrifugal pump, simulation and control software where the pump and a section of pipe. The second phase was executed in the fall of 2016 by two Capstone Project teams (see the cover sheet) whose crude oil pump station simulation and optimization design won them 1st place and the Engineering Design Showcase event. Phase 3 is the design of a functional scale model of a crude oil pump station and a section of pipeline. Phase 4 teams will use the Phase 3 design to construct (build) and test the scale model using PLC software developed by the Phase 1 and 2 teams. Phase 3 Project Description --------------------------- The project is to design a functional scale model of a crude oil tank farm, pump station and length of pipeline. The tank farm will have 3 “oil” storage tanks for low, medium and high viscosity liquids. The pump station will have 4 pumps, 4 motors and 4 variable speed drives. Students must formulate and provide mixing instructions for three different water based colored liquids to simulate low, medium and high viscosity oils. The “pipeline” must of sufficient length to put adequate load on the pumps. The project includes design a metal support structure (frame) and crating. The purpose of the model is to test batch change control and optimization algorithms and compare results to high-resolution simulation results. Siemens also plans to use the model as a demonstrator at industry trade show events in North America. Students are encouraged to validate hydraulic operation, performance and calculations (flow, pressure, water hammer, temperature rise etc.) using appropriate software. The electrical design must be compliant with the National Electric Code standards for control panels. The project teams may produce a 3D printed model of the pump station scale model however this is not a required deliverable for this project. Siemens Sponsoring Mentoring Representatives -------------------------------------------- Ted Fowler prepared the project description and will attend the kickoff event on January 17th 2017 with two Siemens colleagues, Bill Edinger and Jim Salerno (both Penn State Alumni). After the kickoff event Bill and Jim will assume and share the lead role as project sponsors and mentors, participate in weekly network meetings with the Capstone Project teams and attend the Engineering Design Showcase Event in April. Fowler will available to consult on a limited basis. Specifications and Deliverables ------------------------------- Preliminary project specifications are listed in drawing PSU-Prj3-2017-Spring-Specifications-001. Project deliverables are listed in drawing PSU-Prj3-2017-Spring-Deliverables-001. All project deliverables will be used by future Capstone Project teams to purchase equipment, build and test the scale model. Safety and Design ----------------- Designing for safety is paramount. Liquids under pressure escaping piping due to cracks or failed joints can cause bodily. Electrical safety is equally important, electrocution from equipment powered standard 120VAC outlets can result in death. Water and electrical equipment, , circuits and conductors must never meet. Frequent design reviews with respect to safety are required.

Requested Dept.: Chem, ESM, Electrical, Mechanical

Requirements: none


Sikorsky, A Lockheed Martin Company

Contact: Maryam Khoshlahjeh and Frank Krzyzanski

Address: 6900 Main Street, Stratford, CT 06615

Project Title: Additive Manufacturing design project, using a Sikorsky Legacy part

Description: Students will analyze conventionally manufactured part(s) and redesign them for additive manufacturing. Students can utilize tools such as topology optimization, finite element analysis, and engineering judgment to create an optimal part design. The optimized design will be measured against the following categories: weight, cost, and performance metrics. Weight will be compared to the baseline weight. A reasonable cost estimate of the conventionally manufactured part will serve as a baseline to compare to. The performance metric may include an evaluation of the optimized design compared to all of the part requirements. Sikorsky will provide (3) representative part packages for analysis, which will include part drawings / 3D models. Depending on resource and schedule constraints, the students will analyze one or all of the parts. Each representative part will provide for a different additive manufacturing use case. Examples of use cases include: part consolidation, material conversion, and weight reduction. Part consolidation will focus on combining multiple parts into one, material conversion will focus on converting from one metal alloy to a different alloy, and weight reduction will focus on reducing the weight of a polymer based component.

Requested Dept.: MatSci, Mechanical

Requirements: none


SMARTSEAT

Contact: CHUKWUNONSO ARINZE

Address: 1401 East 55th Street, Unit 1001N, CHICAGO, IL 60615

Project Title: SMART CAR BABY SEAT

Description: The objective of this smart car baby seat is to remind users of the presence of a child in the car during a journey. This is important because such a technology can help in preventing and reducing the instances of hot car deaths. There are several technologies aimed at solving these problems. However, these technologies are unpopular for several reasons such as : ad hoc to pre existing car baby seats, complex operation and denial - refusal of parents to buy such devices since their use imply negligence and forgetfulness on the part of the parent. Therefore, there is a need to incorporate this technology to serve as a REMINDER as opposed to one that ALARMS or TRIES to save a baby. We believe such a friendly reminding technology will be more acceptable to parents than their counterparts. Each time the car comes to a halt, a friendly human voice reminder says “Baby in the car” as well as other fancy details like the baby’s weight, temperature of the car cabin environ, speed of the car, traffic, and other random facts. The idea is to sub consciously remind the user that the baby is in the car by stating fancy facts. It may also possess some conspicuous kind of lighting to attract user attention during such reminders. A big challenge is determining when a car halts due to traffic or a temporary stop versus when it comes to a permanent stop. This difference is important as we would want the reminder for the permanent stop to be more "forceful and pointed", since the journey has ended.

Requested Dept.: Bio, Electrical, Mechanical

Requirements: Confidential, Intellectual


The Boeing Company 1

Contact: Brianna Wendt

Address: 1 South Stewart Ave, Ridley Park, PA 19078

Project Title: Mars Rover Project - Team 1 - GLOBAL with Melbourne

Description: Boeing will challenge two teams composed of Mechanical, Electrical, and Computer Engineers to design, build, test, and demonstrate a vehicle designed to explore Mars. As the world is embracing the idea of inhabiting Mars, there is opportunity to use existing space technology to transport rovers to the surface of Mars to gather information. It is the students’ mission to create a vehicle that can navigate a planet where GPS cannot be used, traverse unusual terrain, and gather information vital to researching the likelihood of survival on Mars. Students will be required to design and build a vehicle that can handle Mars-like terrain, being uneven, shifting surfaces with minimal grades. The vehicle will need to visually identify samples which will be rocks of various shapes and weights not to exceed 100 g (the size of a racquetball). In addition to navigating terrain and collecting samples, the rover will be piloted remotely with First Person View (FPV) cameras, simulating an actual rover on Mars. Students at the University of Melbourne will work with the Penn State teams to program the rover to map its path so it can return to home base autonomously without using GPS. Melbourne students will also work to design a system that can be piloted either locally by Penn State students or long-distance by the students in Australia. The goal of this project is to combine the designed structural components (chassis, wheels/treads, rock pick-up, etc.) with the necessary electronic components (motors, cameras, battery, transmitter, etc.) resulting in a fully-functional Mars rover that can handle shifting terrain and be piloted with FPV cameras by the team in Melbourne or locally by the Penn State students. The teams will demonstrate their vehicles in a competition at the end of the semester, on the day of the Learning Factory Showcase. Students will be challenged to collect as many samples as possible within a certain timeframe. The competition will likely occur outside, weather permitting.

Requested Dept.: CSE, ESM, Electrical, Mechanical

Requirements: none

Mars Rover Project - Team 1 - GLOBAL with Melbourne


The Boeing Company 2

Contact: Brianna Wendt

Address: 1 South Stewart Ave, Ridley Park, PA 19078

Project Title: Mars Rover Project - Team 2 - GLOBAL with Melbourne

Description: Boeing will challenge two teams composed of Mechanical, Electrical, and Computer Engineers to design, build, test, and demonstrate a vehicle designed to explore Mars. As the world is embracing the idea of inhabiting Mars, there is opportunity to use existing space technology to transport rovers to the surface of Mars to gather information. It is the students’ mission to create a vehicle that can navigate a planet where GPS cannot be used, traverse unusual terrain, and gather information vital to researching the likelihood of survival on Mars. Students will be required to design and build a vehicle that can handle Mars-like terrain, being uneven, shifting surfaces with minimal grades. The vehicle will need to visually identify samples which will be rocks of various shapes and weights not to exceed 100 g (the size of a racquetball). In addition to navigating terrain and collecting samples, the rover will be piloted remotely with First Person View (FPV) cameras, simulating an actual rover on Mars. Students at the University of Melbourne will work with the Penn State teams to program the rover to map its path so it can return to home base autonomously without using GPS. Melbourne students will also work to design a system that can be piloted either locally by Penn State students or long-distance by the students in Australia. The goal of this project is to combine the designed structural components (chassis, wheels/treads, rock pick-up, etc.) with the necessary electronic components (motors, cameras, battery, transmitter, etc.) resulting in a fully-functional Mars rover that can handle shifting terrain and be piloted with FPV cameras by the team in Melbourne or locally by the Penn State students. The teams will demonstrate their vehicles in a competition at the end of the semester, on the day of the Learning Factory Showcase. Students will be challenged to collect as many samples as possible within a certain timeframe. The competition will likely occur outside, weather permitting.

Requested Dept.: CSE, ESM, Electrical, Mechanical

Requirements: none

Mars Rover Project - Team 2 - GLOBAL with Melbourne


The Bucktail Medical Center

Contact: Tim Reeves

Address: 1001 Pine Street, Renovo, PA 17764

Project Title: Emergency room redesign in two stages

Description: Stage I - Increase efficiency of staff movements and improve access to patient and supplies. With the current configuration, staff work stations face a wall rather than facing the patient. Capacity is limited to two permanent bays, other areas need to be set up on demand. The only privacy between the two treatment bays is a curtain, making privacy and confidentiality very difficult. Lighting is provided by non-task oriented over-head lighting. This stage will involve: 1. Way-finding 2. Lighting 3. Privacy 4. Triage 5. Security 6. Staff work stations 7. Equipment storage Stage II - A complete redesign of the ER. This could include expansion of the physical space. The goal of the redesign is to increase patient capacity, increase privacy, better control patient traffic (including a dedicated ambulance bay ), better address infection control, improve staff work areas, improve security for patients and staff, and equipment storage. This stage will involve: 1. Way-finding 2. Finishes and robustness 3. Lighting 4. Privacy 5. Infection control and hand hygiene 6. Ambulance bay/reception 7. Documentation areas

Requested Dept.: EDG, ESM, Industrial

Requirements: none

Emergency room redesign in two stages


The Shanghai General Fan Co.,Ltd.

Contact: Hang Su

Address: No. 529, Yuandong Rd., Fengpu, Fengxian, , Shanghai, 20140

Project Title: Optimal design of an axial fan - GLOBAL PROJECT with SJTU

Description: T35 series fan is a low-pressure axial fan which is widely used; it was designed many years ago. Due to the simplicity of manufacturing process, compact size and the convenience for installation, it is widely accepted by the users. However, with the improvement of the energy efficiency standard of the fan, how to achieve the efficiency value is a question stipulated in the GB19761-2009 by improving the aerodynamic performance structural parameters under the premise of guaranteeing the original flow and full pressure performance requirement. Deliverables: 1. Through the project cooperation, we hope to use T35 series fan as the prototype to experiment, to achieve the efficiency value of GB19761-2009 under the premise of guaranteeing the original flow and full pressure performance requirement. 2. Optimize and improve the design through physical testing and verification of T35-6.3A axial fan; 3.By optimizing the impeller, find the optimum value of the blade size and the installation angle (leaf blades still need to be veneer twisted welding blades ); 4. By optimizing the design of fan chassis and its circulation accessories, further enhance the overall performance of the fan.

Requested Dept.: Mechanical

Requirements: none

Optimal design of an axial fan - GLOBAL PROJECT with SJTU


Transverse Myelitis Association

Contact: Linda Malecky, Gabrielle (GG) DeFiebre, and Pauline Siegel

Address: 1, 1, 1 1

Project Title: A device to open heavy doors

Description: The objective of this project is to create a portable device to facilitate opening "heavy" doors. The target user population includes people in wheelchairs and people with compromised arm strength. "Portable" means that an individual user should be able to carry it easily--and inconspicuously--along with the other sundries one needs to get through a day. It should be small (e.g., fit in a purse or bag), not weigh too much, etc.

Requested Dept.: Bio, Mechanical

Requirements: none


TRS Technologies, Inc.

Contact: Wesley Hackenberger

Address: 2820 E. College Ave., State College, PA 16801

Project Title: Precision Chamfering of Piezoelectric Crystal Plates for Medical Ultrasound

Description: TRS produces a new single crystal piezoelectric material for medical ultrasound imaging that is rapidly replacing the existing ceramic components. Customers are passing difficult specifications for these components down to suppliers like us who must rapidly improve manufacturing capabilities to meet the new requirements. The crystal components are generally rectangular plates ~ 60mm x 15mm x 0.2mm (or less). The plates are ground to precision thicknesses with tolerances of +/- 5 to 3 um. A particularly difficult new feature requested is a precision chamfer along all four edges in the longest dimension. For example, one customer is requesting a chamfer that is 35 um wide with a tolerance of +/- 10 um. The chamfers are meant to remove damage from the part edges without interfering with subsequent process steps at the customer. TRS has two provisional processes for creating these chamfers. The first uses a simple Dremel tool grinder to smooth or round the corners of the parts. This does not provide precision chamfer dimensions, and we have found it may not be adequately removing damage. The 2nd method uses a precision dicing saw with a “V-blade” to form the chamfer by making a partial 45° cut along the length of the part. This gives a high-quality chamfer but maintaining tolerance is difficult and extremely time consuming. TRS is interested in process refinements or new processes that can improve the tolerance of the chamfers and increase the manufacturing throughput. We would be open to a range of solutions including: 1) Dedicated chamfering equipment – cost must be < $50,000 and preferably < $25,000. 2) Upgrades to existing equipment, especially to precision dicing saw, to improve the chamfering process – similar cost to above 3) Development of fixtures to facilitate the chamfering operation or to enable a different chamfering process (e.g. fixtures to improve the dicing-chamfer operation or fixtures that enable chamfering by lapping). The crystal material is very unique with unusual mechanical properties. It is a brittle oxide but with an elastic stiffness similar to epoxy. It also has a limited range of plasticity and can be damaged by stresses exceeding its very low yield strength. These unique properties can greatly affect the process parameters needed to manufacture components.

Requested Dept.: Industrial, Mechanical

Requirements: Intellectual

Precision Chamfering of Piezoelectric Crystal Plates for Medical Ultrasound


Twigs Management LLC

Contact: David Richards

Address: 209 Twigs Lane, State College, PA 16801

Project Title: Club Claw Golf Club Headcover

Description: Twigs Management LLC Club Claw Cover Product Overview August 2016 CONFIDENTIAL. Material contained within is considered the proprietary and intellectual property of Twigs Management LLC. PRODUCT OVERVIEW Removing and replacing the golf headcover on your driver and other clubs has always been a clumsy two-handed process. Most golfers remove the covers at the beginning of a round and place them in the cart. The club rattle against each other in the bag during the round, defeating the original purpose of the headcover. SOLUTION Our proposal is to create a headcover that requires one hand to remove and no hands to replace, making the process easier. REMOVAL OPERATION The shaft area of the headcover would serve as a “handle”, which when pulled downward with one hand, would pop open a claw like cover. The operation would look similar to a flower opening. When closed the mechanical claw elements (covered in fabric or other cushioned material) would protect the club. Pulling down on the “C” shaped shaft of the cover that fits around the stainless steel golf shaft would OPEN the cover. REPLACING THE COVER Replacement would occur in one of two ways. During normal operation and dry conditions, golfer would place the open cover on the ground. After the shot, they would simply tap the club on the center of the open headcover and a mechanical trigger would close the cover around the club. During wet or sloppy conditions, when a golfer would not want the cover out in the grass, it would simply be pressed against the club with one hand. ENGINEERING CHALLENGE TO BE SOLVED BY PSU Designing the mechanism at the core of the cover which a.) Opens when the shaft is pulled, and b.) closed when tapped in the center. Crude designs by the inventor can be shared as a starting point.

Requested Dept.: EDG, Mechanical

Requirements: Confidential, Intellectual


Tyber Medical LLC

Contact: Eric Dickson and Jeff Tyber

Address: 83 South Commerce Way, Suite 310, Bethlehem, PA 18017

Project Title: Project Unite

Description: ORTHOPEDIC EXTREMITY PROJECT SCOPE December 20, 2016 1. Project Background and Description With technology advancing in the orthopedic extremity market, many companies are exploring new technologies in plating that will 2. Project Scope Develop a low profile, locking, anatomical plating system for the extremities 3. High-Level Requirements Tyber medical The new system must include the following: • Ability to lock to the plate with a unique locking mechanism • Ability to integrate a 30° variable angle locking mechanism • Ability to integrate a dynamization feature • Free of current IP 4. Specific Exclusions from Scope • Spine • Craniomaxillofacial 5. Implementation Plan • Cad designs of forefoot, midfoot, hindfoot plates, variable angle locking mechanism and dynamization feature • Prototypes APPROVAL AND AUTHORITY TO PROCEED We approve the project as described above, and authorize the team to proceed. Approved By Date Approved By Date

Requested Dept.: Bio, Mechanical

Requirements: Intellectual

Project Unite


Tyco (China) Investment Co. Ltd. 1

Contact: Xiaodong Yang and Ruimin Lui

Address: Building 40(Kailong), Xinjinqiao Rd 1888,Pudong,Shanghai, Shanghai, 20120

Project Title: Critical features study of new standard Helmets for firemen - GLOBAL PROJECT with SJTU

Description: Ministry of Public Security released a new standard GA44-2015, Helmets for firemen, last year. It has many features update comparing with GA44-2004. Such as Impact, Heat, Burn test. We don’t have this kind of product yet but would like to develop.

Requested Dept.: Bio, Industrial, MatSci, Mechanical

Requirements: Confidential, Intellectual


Tyco (China) Investment Co. Ltd. 2

Contact: Aaron Gu

Address: 6F, No. 40, KaiLong Elite East Building, 1888 XinJinQiao Roa, SHANGHAI, sh 20120

Project Title: Gas cylinder management system - GLOBAL PROJECT with SJTU

Description: This project intend to build a cloud software platform to manage the gas cylinders through the whole process, including gas cylinder filler, seller, customer, maintennace and Tyco; all the parties are able to play in the software platform with different role & responsibilities.

Requested Dept.: CompSci, EDG

Requirements: none


Tyco Retail Solutions

Contact: Athena Zhao

Address: Floor 6, Building 40, Lane 1888 Xin Jinqiao Rd., Pudong, Shanghai CHINA, 201206

Project Title: Footware Tag - GLOBAL PROJECT with SJTU

Description: To address the customer needs, it is necessary to develop a footwear tag which will be applied on the flat-heel shoes without lace holes or some other features that the lanyard/cable can pass through. There is one footwear tag in the market but for the high-heel shoes only. It utilizes the hook and cable loop to lock the tag on the high-heel shoe. For this project, the assumption is that there is one switch on the tag. After the tag attached on the shoe, the switch is triggered. If someone wants to remove the tag from shoe without the detacher detaching, the switch goes back its original status, the tag begins to alarm by itself. Of course, if the tag is detached by the magnetic detacher and then removed from the shoe, it does not alarm in the process. The scope of this project includes the mechanical parts design, PCBA design, firmware developing and appropriate components selection (Main the switch, button cell battery, chips). Consider the actual application surroundings, we give below requirements: 1. Can be detached by our MKD31 detacher. 2. Does not interfere with customer “Trying on” experience. 3. Normal “ Trying on” action can’t cause the tag alarming. 4. Cost evaluation and control in the design. 5. Final DEMO is necessary with prototypes.

Requested Dept.: CompSci, CSE, Electrical, Mechanical

Requirements: Confidential, Intellectual

Footware Tag - GLOBAL PROJECT with SJTU


Tyco Security Products

Contact: Frank Zhao

Address: 6F, East Building 40, No.1888 New Jinqiao Rd.,Jinqiao, Pudon, Shanghai, NA 00000

Project Title: Raspberry Pi Camera - GLOBAL PROJECT with SJTU

Description: This project is to build a surveillance camera based on a Raspberry Pi micro-computer which records HD video. The camera should be wireless and movable with remote control by mobile app. The video should be recording by Tyco ExacqVision. The housing shape of the Raspberry Pi Camera could be small car or spider or self-balancing robot etc. The Raspberry Pi is a series of credit card-sized single-board computers developed in the United Kingdom by the Raspberry Pi Foundation. It's a low-cost micro-computer that is able to run Linux, Ubuntu or Windows 10 IoT Core and has endless extension possibilities. Except Raspberry Pi 3 Model B, it will also use Raspberry Pi Camera Module - This module was specially build for the Raspberry micro-computer. It has a connector to be plugged directly into the Raspberry board and supports HD video up to 1080p. https://www.raspberrypi.org/

Requested Dept.: CompSci, CSE, Electrical, Mechanical

Requirements: none


UPMC Susquehanna

Contact: Anne Holladay

Address: 215 E. Water Street, Muncy, PA 17756

Project Title: Employee Engagement and Satisfaction

Description: Susquehanna Health Skilled Nursing and Rehabilitation Center (SN & RC) is 138 bed long term care facility attached to the Muncy Valley Hospital. We currently employ approximately 170 employees, full time, part time and per diem. The organization recently conducted an employee satisfaction survey and received the designation of Employer of Choice for its high score. SN & RC did not score as well as the organizational overall score. Therefore, we are interested in an IE team to formulate a plan for improving our employee satisfaction scores, developing a monitoring tool for employee satisfaction and researching best practices for employee satisfaction for long term care employees.

Requested Dept.: Industrial

Requirements: none


Volvo CE North America, LLC

Contact: Mike Macdonald

Address: 312 Volvo Way, Shippensburg, PA 17257

Project Title: Ultrasonic Drum and Screed for Road Construction

Description: Background Fresh, hot asphalt is sticky. That can cause problems during the road paving process. The hot asphalt can stick to the equipment being used to make the road, thus degrading the road as it is being built. In particular, there are two pieces of construction equipment that are in direct contact with the asphalt and are affected by this problem; the asphalt paver and the asphalt compactor. The asphalt paver comes first, and deposits the hot asphalt onto the road surface to be paved. The rear of the asphalt paver is called the ”screed.” The bottom of the screed is a metal plate that is in direct contact with the hot asphalt. The screed is used to control the thickness, contour, and smoothness of the asphalt. The screed is the predominantly black structure on the right hand side of the photo. The asphalt compactor follows the paver, and is used to increase the density of the hot asphalt, thus improving its load bearing capability and longevity. The asphalt compactor typically has two similar steel drums. The drums are in direct contact with the hot asphalt. They perform the compaction due to both static and dynamic forces. The static force comes simply from the weight of the machine, and the dynamic force comes from the vibration of the drums. (The details of how the drums vibrate, which is in the 30 Hz to 70 Hz range, can be explained at a later time.) Current Solutions to the Problem For the paver screed, the solution that is used by all pavers is to heat the bottom of the screed to approximately the same temperature as the hot asphalt, about 300 degrees F. This heating is done either with diesel burners or with electric resistance heaters. These solutions require either a burner system or an electric generator with the associated heaters. For the compactor drums, the only solution used by all is to keep the drum wet with water. This solution requires the machine to have water tanks, a water distribution system, and a supply of water at the job site. Ultrasonic Idea If the paver screed and the compactor outer shells of the compactor drums could be made to vibrate ultrasonically, this might prohibit the hot asphalt from sticking. (This idea is similar to the use of ultrasonic vibration to clean jewelry.) Then the heaters, associated fuel use, water systems, etc. will not be needed. The end customer would experience improved Productivity, Reliability, Fuel Economy, and more Simplified Operation of their compactors and pavers. Feasibility Study This project is a feasibility study for whether ultrasonic vibrations will actually prohibit hot asphalt from sticking to steel. The following is not in any way intended to impose restrictions on this study, but just to give an idea of what this study might include. • Use small steel plates for the testing (4”x6”, for example) • Have four conditions for testing: o bare ambient temperature plate o ambient temperature plate with water coating o hot plate o ultrasonically vibrated plate • Press the plates into hot asphalt with an appropriate force to simulate the pressure under the paver screed and the compactor drum • Test using different ultrasonic frequencies • Literature study on best frequencies to use for cleaning • Determine the natural frequencies of the test plates that are in the ultrasonic range • What ultrasonic transducers would be best to use • How much energy would be needed to vibrate the screed plate and the drum shell ultrasonically • Are there other important parameters This idea is already protected by a US patent. Desired Deliverables • Best frequencies to use • Transducer options, with pros and cons of each • Test report • FEA (if done) • How much power would be needed for a full size paver or compactor

Requested Dept.: Chem, ESM, Electrical, MatSci, Mechanical

Requirements: Intellectual

Ultrasonic Drum and Screed for Road Construction


Volvo Group, North America

Contact: Sam McLaughlin

Address: 13302 Pennsylvania Ave, Mercersburg, PA 17236

Project Title: An EGR System Design for a Diesel Research Engine - GLOBAL PROJECT with Chalmers University

Description: External Exhaust Gas Recirculation (EGR) feeds the exhaust gas from an engine back into the intake manifold, primarily for control of NOx emissions. An EGR system is to be developed for the experimental work on a Volvo research engine at University of Michigan. SCOPE OF WORK 1.Research the operational needs and functions of an EGR system. Communicate plans and understand concepts based on discussion with UM, Volvo, and Volvo CTP. 2.Develop an engineering design based on engine specifications, EGR specifications (mass flow, exhaust temperature and space availability), calculations and simulations of the required system. 3.Design modifications of the engine manifold flow paths to connect the EGR flow path. 4.Design a control and measurement system for the EGR throttle valve to vary the EGR flow in the intake manifold using existing EGR cooler and control valve. This involves achieving correct flow rate and air-to-fuel ratios for various load applications. 5.Establish instrumentation for EGR variables (mass flow sensor, thermocouples, CO2 content) 6.Provide engineering layout and prints of all components.

Requested Dept.: Energy, EDG, ESM, Industrial, MatSci, Mechanical

Requirements: Confidential

An EGR System Design for a Diesel Research Engine - GLOBAL PROJECT with Chalmers University


Volvo Trucks 1

Contact: Peter Gullberg

Address: Volvo Group Trucks Technology, Goteberg, SE 40508

Project Title: Research and Develop new fan blade shape, “divided fan blade” step2 - GLOBAL PROJECT

Description: Background: A novel fan rotor blade has been presented to Volvo, “divided/double fan blade”. See patent US 7,396,208 B1. With reference to new double wing airplanes this fan design claim to have higher efficiency potential than conventional blade. See http://www.popsci.com/technology/article/2012-04/jets-future This project is a continuation from last year’s project, reported in: http://publications.lib.chalmers.se/records/fulltext/238943/238943.pdf Task (expected emphasize in bold): 1. Research and investigate this new design of fan blade, prior art, known technology, potential and limitations. 2. Develop a fan blade concept (3D-CAD) to fit a truck installation. The current design has open tip without shrouding, the truck will house a shroud around this fan rotor 3. Assess the aerodynamic performance of this developed fan blade and the interaction between blade and shroud. Compare this to current know fan technology and compare this to the baseline fan geometry (seen in figure above). 4. Re-iterate design based on learnings, Re-iterate assessment. 5. Prototype and test fan performance. Deliverables: • Research documentation of this technology • CAD design of the fan blade • Aerodynamic performance assessment of fan blade (simulations and test results) • Technical specification. • Validation test specification, verification plan & Test report. • Product cost estimate. • A functional prototype.

Requested Dept.: Mechanical

Requirements: Confidential, Intellectual

Research and Develop new fan blade shape, “divided fan blade” step2 - GLOBAL PROJECT


Volvo Trucks 2

Contact: Per-Lage Gotvall

Address: Götaverksgatan 10, Gothenburg, VG 40508

Project Title: tool for mounting/demounting of rotational design elements for use by robots and humans - GLOBAL

Description: Background: Collaborative robots are entering the market rapidly. Applications for those kind of robots are often intended to be the same kind of mounting/de-mounting operations as today are performed by humans. That implies that tools used for those operations shall sometimes be used by humans and sometimes be used by the collaborative robots. This will require a complete new type of control and sourcing of actuators in the tools as well as also addressing quite complex ergonomic questions. Tasks: 1. Learn to work in a global product development team 2. Learn how those operations are performed in industry today 3. Learn what it means to have a workstation where humans and robots are working together 4. Set up the technical, ergonomic etc. requirements for the tools 5. Make some design concepts, evaluate and select one 6. Design the selected concept 7. Build a prototype using additive manufacturing technologies (3D-printing) 8. Define technical specification for the unit, including temperature demand, vibration, resistance to oil etc. 9. Test the tools Deliverables: • CAD design • Technical specification. • Validation test specification, verification plan & Test report. • Product cost estimate. • A functional prototype.

Requested Dept.: ESM, Industrial, Mechanical

Requirements: Confidential, Intellectual


Volvo Trucks 3

Contact: Timo Kero

Address: Gropegårdsgatan, Göteborg, VG 40408

Project Title: Modularization of Storage Spaces in Cabins with focus on cabinets for multi bra - GLOBAL PROJECT

Description: Volvo Group Truck Technology develops and produces for nearly all markets in the world, and for truck drivers the cabin provide not only their workplace, but the environment where they spend a large portion of their time over long periods of the year. Naturally, preferences differ between drivers and between markets. Meanwhile, there is a rationalize how to manufacture these, something that drive “commonality” between the range of solutions offered. It is important that both functionality and individual preferences are met to a high degree without comprising efficient production. The overall task is to develop and suggest modularized cabinet equipment, based on expected functionality and accounting for production commonality. 1. Gather experience and expectations for US and Swedish drivers 2. Identify targeted storage solution 3. Develop new/re-designed modular cabinet solution addressing expectations found 4. Evaluate produceability and flexibility for a modular solution 5. Prototype and gain feedback on proposed solutions 6. Propose and recommend way forward Deliverables: • Documentation of driver experience and expectation on storage • Functional analysis • CAD Definition of modular storage solution • Technical Specification • Evaluation of produceability and flexibility/bandwidth of solution • Structural Evaluation (stiffness, strength, functionality of moving parts) • Validation test specification, verification plan & Test report. • Product cost estimate. • A functional prototype.

Requested Dept.: EDG, Industrial, Mechanical

Requirements: Confidential, Intellectual

Modularization of Storage Spaces in Cabins with focus on cabinets for multi bra - GLOBAL PROJECT


Well Master Corporation

Contact: Dan Nelson

Address: 400 Corporate Circle, Suite K-M, Golden, CO 80401

Project Title: Manufacturing Gap Analysis & Continuous Improvement - GLOBAL PROJECT WITH SJTU

Description: DESCRIPTION: The oil and gas industry is regularly changing and creating new governing specifications to continuously improve the state of the industry. These improvements are very important as they create positive impacts on worker safety, cleaning up the environment, improve efficiencies, and standardize across global manufacturers. In the coming year, the American Petroleum Institute will be releasing a new standard around a specific piece of natural gas well equipment, called a Lubricator. This project will focus on auditing Well Master and its suppliers to the API specification as well as evaluation of other processes for improvements that can be made. Final assembly and Quality checks are done at Well Master Corporation in Golden, CO. The lubricators are machined with some assembly and initial quality checks in Changzhou, China. OBJECTIVE: There are 3 main areas of focus for this project as well as some areas to review for possible improvements. 1) Audit of Factory manufacturing and quality processes: Ensure that all materials used and quality processes performed are in accordance with the API standard. This includes: a. Raw materials, b. Welding process & procedure, as well as welding filler rod used c. QC and testing documentation, d. Report out of inspection data to WMC in Golden. 2) Audit of Assembly and Quality processes at WMC: Review the processes at WMC from receiving to shipment for adherence to the API specification. Specific focus on: a. QC inspection process and efficiency b. Ergonomics surrounding lifting and movement of lubricators c. Creation of Inspection and Testing Packet (ITP) d. Applicable safety decals and warning labels for the lubricator e. Customer delivery experience (possible trip to customer location in PA) f. Assembly and Operating instructions 3) Traceability of raw materials and processes performed: Review and creation of processes around tacking and maintaining records for the processes each lubricator undergoes. Lubricators are serialized, but how do the original material certs and specific welding and tests get tracked from start to finish. WMC & Customer would need to be 100% certain what paperwork corresponds to which serial #, and be able to generate and send the customer a report out. A suggested split in the project is to have the SJTU team visit the factory for item 1 above, and the Penn State team would then travel to Golden, CO to audit for item 2. Both teams would collaborate on item 3 to focus on traceability and transfer of information from the factory to Well Master to the customer. DELIVERABLE: The completion of the objectives should result in a packet that provides recommendations that are feasible to be implemented and achieve the three desired outputs of a quality, repeatable process, fully documented that enables cost reduction.

Requested Dept.: Industrial, MatSci, Mechanical

Requirements: Confidential

Manufacturing Gap Analysis & Continuous Improvement - GLOBAL PROJECT WITH SJTU


X Material Processing

Contact: Matt Woods

Address: 200 Innovation Blvd, State College, PA 16803

Project Title: Multi-Metal 3D Printing - Material Recovery

Description: OVERVIEW: Selective Laser Melting is a form of 3D metal printing. It is gaining popularity in industries such as aerospace, medical,automotive, and manufacturing because it can be used to make complex and high performance components with very little material waste and many new design freedoms. The technology is currently limited to producing parts made up of only a single material at a time. XMP is developing a complete solution to this problem. Without an effective material recovery system, the XMP solution may prove to be uneconomical, as most of the material processed powder would become scrap. This project has two components to it: The first component is ready for industrial scaling and the second may require further research, design, and analysis to improve efficiency. OBJECTIVE: The team will be tasked with the scaling of the current prototype to become a functional industrial powder separation system. The current prototype can separate powders on a g/min. The team will be tasked with the scaling of this prototype such that it can separate materials in the range of kg/min. The second component to the two-part process will need to be researched and re-designed in order to improve the separation efficiency of the metal powders. More specifically, the second stage will be separating primarily a copper alloy and an Inconnel superalloy.

Requested Dept.: Industrial, MatSci

Requirements: Intellectual

Multi-Metal 3D Printing - Material Recovery