Project Details

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Ceiling Hanger Redesign for Improved Structural Performance and Installation Reliability

Company: TMP Manufacturing Company, Inc.

Major(s):
Primary: ME
Secondary: IE

Non-Disclosure Agreement: NO

Intellectual Property: NO

Tafco is a long-established U.S. manufacturer of walk-in coolers, freezers, and modular insulated panels serving commercial, industrial, government, and pharmaceutical customers. Our primary facility for this project is located in Clearfield, Pennsylvania, approximately 50 miles (about a one-hour drive) from State College. One critical component in our system is the ceiling hanger, a sheet-metal bracket used to suspend ceiling panels safely and securely. Although our current design meets code requirements, it creates challenges during installation: thicker hangers increase the gap between adjacent panels by acting as a wedge, while thinner hangers risk mechanical failure where the sheet metal engages internal pins within the panel. We are seeking a creative engineering approach to redesign this hanger system so that it can reliably support required loads without contributing to panel separation or premature failure. Students will explore both the hanger and panel interface, considering how geometry, material thickness, and engagement methods influence performance. The design space includes evaluating whether increased hanger length could allow the foam core and adhesive inside the panel to carry more of the load, rather than relying solely on sheet-metal strength. Other innovative concepts or alternative fastening methods are also welcome. The project requires an understanding of the trade-offs between mechanical strength at the metal-pin interface and the structural contribution of the foam-adhesive system, supported by appropriate modeling and analysis. A major component of the project will involve hands-on prototyping and physical testing. Students will fabricate prototype hangers, embed them into representative panel samples, and perform load tests (targeting approximately 900 pounds of pull force to achieve the required safety factor). Tafco will provide access to testing equipment, facilities, and expert guidance. Because sheet-metal fabrication methods are central to the work, students who are not already familiar with these processes must be willing to complete relevant Learning Factory training and collaborate closely with TMP mentors throughout the prototyping phase. The final outcome should be a redesigned hanger solution, supported by testing and engineering justification, that maximizes load capacity, minimizes installation issues, and satisfies building-code constraints while improving overall panel performance.