Current Projects

Spring 2025 Projects

Check majors below to filter projects by those majors only:

 

Legend: 1 = Primary Discipline | 2 = Secondary Discipline | 3 = Optional Discipline(s)

Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Actuated Medical, Inc. GripTract-GI Endoscopic Tissue Manipulator Hylbert, Lyndsey 1 0 0 0 0 2 0 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Actuated Medical has an FDA cleared medical device – the GripTract-GI endoscopic tissue manipulator (www.griptract.com). It is a single-use device that connects to the distal end of an endoscope without occupying the working channel. GripTract assists clinicians with optical visualization, diagnosis, and endoscopic treatment. We are interested in developing the indications for foreign body retrieval and food impaction removal. The project may include the student team conducting clinician interviews, assessing market and competition, developing & building a test model, drafting test protocols and conducting pilot testing for a regulatory submission. If time permits, design and build a ‘net’ accessory that would flip over the GripTract fingers to hold the foreign body as the endoscope is removed from the patient.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Anita Ferraco Woodman, LLC Carisma Smith, Tahira Reid 0 0 0 0 0 1 0 0 0 3 3 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Background:

As an experienced industrial engineer with a strong passion for mentoring and innovation, I've had the privilege of sponsoring two successful Learning Factory projects over the past seven years, as a full-time staff member for Penn State IT. These experiences have allowed me to work closely with talented students, guiding them through the entire project development process.

Now, I'm excited to continue this tradition and offer another team of bright, innovative students the opportunity to learn and grow. This time, I'm sponsoring a Learning Factory team through my own personal business. With over 15 years of experience in project management, facilitation, and continuous improvement, I'm committed to providing the guidance and support needed to bring your ideas to life.

Problem Statement:

Many individuals who use pedestal or wall-mount sinks face the daily frustration of having no convenient surface to place personal grooming items. This often leads to items being haphazardly placed on the toilet or floor, posing a risk of contamination and accidents. Additionally, reaching for items across the room or under the sink can be inconvenient and time-consuming. There is a clear need for a practical and hygienic solution to this common problem.

Value Proposition:

The Carisma project aims to design and develop a sleek and functional product that addresses the common challenge of limited storage space in bathrooms with pedestal or wall-mount sinks. By providing a space for personal grooming items, this design eliminates the need to place items on the toilet or floor, reducing the risk of contamination and accidents. This sleek and functional design will enhance bathroom organization and personal hygiene, and promote a more efficient and enjoyable grooming experience.

Value to the Students:

This project offers a unique opportunity for engineering students to apply their knowledge and skills to a real-world challenge. By participating, you will:
• Gain hands-on experience: Work on a real-world project from concept to prototype.
• Develop critical thinking and problem-solving skills: Identify challenges, brainstorm solutions, and evaluate design choices.
• Enhance your design and engineering abilities: Refine design specifications, create innovative prototypes, and optimize for cost-effectiveness.
• Collaborate with a talented team: Work with your peers to achieve a common goal.
• Learn from an experienced mentor: Receive guidance and support from an industry professional.

By joining this project, you'll not only contribute to a meaningful solution but also contribute to the foundation for your future career.

Deliverables – suggested items to be discussed with team at initiation of project to create agreed upon final list:

• Concept Sketches: Initial sketches exploring various design ideas.
• 3D Models: Digital models of the product, showcasing its form and function.
• Technical Drawings: Detailed engineering drawings specifying dimensions, materials, and manufacturing processes.

Prototyping Deliverables:

• Functional Prototype: A working model demonstrating the product's core functionality.
• Iterative Prototypes: Multiple versions of the prototype, reflecting design improvements and refinements.
Testing and Evaluation Deliverables:
• Design Validation Plan: A document outlining the testing procedures and criteria.
• Test Results and Analysis: Data and insights from testing the prototype.
• User Feedback: Input from users on the product's usability and effectiveness.

Financial Deliverables:

• Cost Analysis: A comparison of different design and material options, assessing their impact on the final product cost.

Documentation Deliverables:

• Project Plan: A detailed plan outlining the project timeline, milestones, and resource allocation.
• Design Journal: A record of the design process, including sketches, notes, and reflections.
• Final Report: A comprehensive report summarizing the project's outcomes, challenges, and lessons learned.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Armstrong World Industries Automated Packaging for Ceiling Tiles Lewis, Alfred (Scott) 0 0 0 3 0 0 0 0 0 2 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Overview
Armstrong World Industries manufacturers acoustical ceiling tiles that are 2x2 (ft) or 2x4 (ft) in size. In the packaging operation, 8 to 12 tiles are stacked in a pile and a protective cardboard sleeve is placed around the stack. The entire sleeved stack is then shrink wrapped and labeled for the Customer. The sleeving operation is currently a human, manual operation.

Armstrong World Industries wants to develop a prototype process that can:
a) Automatically "square up" a stack of tiles in a pile.
b) Measure the "squareness" of the stack to verify stack tolerance is met (TBD) prior to sleeving.
c) Carefully, accurately, and consistently place a protective cardboard sleeve around the stack.
d) Accomplish this by maintaining current or better throughput rates.
e) Measure successful throughput
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
AstaZero AB Drone platform for safety in testing - Chalmers Global Project Smith, Tahira Reid 0 0 1 2 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

AstaZero is a proving ground located deep in the forests outside Gothenburg, Sweden, built to test
advanced automated driving and active safety systems in road vehicles, such as automated emergency brake systems commonly found in modern vehicles. AstaZero is a non-profit organization owned indirectly by the Swedish government and performs independent testing, verification, and certification for its customers.

Previous Capstone projects at AstaZero have focused on using drones to support day-to-day operations. A previous project improved site security by detecting breaks in the fence enclosing the track with the help of AI-image analysis. In contrast, another project developed a safety system for AV testing using drones to detect vulnerable road users.

AstaZero has developed an Autonomous Vehicle Test Operating System (ATOS) to carry out scenariobased testing. This system controls test participants, such as the vehicle under test, crash targets, and surrounding infrastructure. ATOS features functionality that ensures the safe and secure testing of AVs. The previously developed safety system enhances the safety of ATOS; still, interesting research questions relating to video latencies, machine-learning methods deployed on edge-compute, and real-world validation and testing of the system remain unanswered.

Goal

Therefore, this project's goal is to continue developing a software-based system for automated supervision of tests at the proving ground, which will be showcased at the AstaZero proving ground at the project’s end. The showcase will demonstrate a drone-control system that integrates with ATOS to plan drone routes, simultaneously using AI and machine learning-based techniques to detect, e.g., endangered persons or dangerous and/or anomalous behavior of test objects.
The task
Pennsylvania State University students will collaborate with Chalmers University of Technology students in this international project to reach the goal. Your task will be to design, implement, and test a system for detecting dangerous situations during testing, building upon previous students’ work.

1. Understand code and systems produced by previous students.
2. Make a plan for developing new software and integrating it with existing systems based on a
gap analysis between previous systems and the system described in the goal section.
3. Integrate a drone control system with ATOS, enabling the efficient control of drones.
4. Continue development on a vulnerable road user detection method.
5. Deploy signals to ATOS in real-time.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Astrolabe LLC A Feeding Device for Cats with Special Needs Hylbert, Lyndsey 1 0 3 3 0 3 0 0 0 3 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Overview:

This project serves to address common pet needs that are unmet by commercially available products.


Deliverables:

Develop a prototype based on sketch/concept design, OR propose & develop a prototype according to specifications and considerations.

Include a project report that details prototype specifications, schematics, materials used, functional limitations, etc.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
B Braun Medical Inc Flow Detector for Low Flow Rate Applications Lei, Yuguo 1 0 0 0 0 0 0 0 0 0 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Modern healthcare has seen a shift to more at-home care than ever before. It offers patients the benefit of being in their own home, or even mobile around town, while continuing to receive their necessary treatments. One device that makes this possible is an elastomeric pump. The elastomeric pump is like a balloon filled with medication which slowly deflates over time to push the medication to the patient.
One challenge when using these elastomeric pumps is being able to distinguish whether it is actively delivering medication. Flow rates set with these pumps can be as low as 2 ml/hr. As one can imagine, it is hard to visualize the elastomeric balloon deflating since the flow rate is so slow. In a fully functioning system, there is no clear way for the human eye to see the fluid moving that slowly through the tubing.
When a home care patient is unsure if their medication is being delivered, they would need to call their doctor and have it checked by a medical professional. Ensuring they are getting the medication they need is critical, but false alarms can also occur, leading to unnecessary costs and stress for all involved.
The challenge for the project team is to develop a low-cost flow sensor capable of detecting flow at this low rate. The sensor should include visual indicators for the patient to identify that their pump is working. Along with the elastomeric pump market, this type of sensor could be used in various applications like gravity delivery and piggyback sets.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Bus Climate Control Plan For Every Part (PFEP) - Analyze material usage and space requirements necessary to maximize replenishment cycles to our assembly lines. Zajac, Brian 0 0 0 0 0 0 0 0 0 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

PLAN FOR EVERY PART - Need high level analysis of multiple assembly lines. Involving hundreds of part numbers, with highly varying usage requirements.

Project will involve a high level of data analysis, along with information gathering.
Example: Assess supplier packaging (box sizes and quantities).

Need proposals for development of Lean Supermarkets, including layout with space requirements and min/max levels.

Layouts and proposals to maximize material presentation on lines, based on just in time replenishment cycles.

Proposal should include an estimated cost and projected ROI to provide to sponsor at the conclusion of this project.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Carlton "Rich" McCracken Jr. 1 Stackable 3D Tic Tac Toe, 1st Project, Redesign and Explore Smith, Tahira Reid 0 0 0 0 0 1 0 0 0 0 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Overview - Objectives:
The first Capstone Design Project concerning the game/therapy board called “Stackable 3D Tic Tac Toe”, S3DTTT, object summary is for adding redesign and exploring the best functional ways of the multiple facets of the three different versions of the game/therapy board. The three different versions are as follows:
[1.] The original board, 3 by 3 bolts, [2.] The “Mega Board, 5 by 5 bolts, [3.] The “Semi Mega Board, 5 by 4 bolts. There is also the exciting and interesting option of the combination of the three different versions. These combination configurations in my patent which is pending, are called “entire collective” game/therapy boards.
Examples of the multiple facets are as follows: [A.] The board being used as a therapy board using many different accessories to develop pinch strength such as our fingers alone, fingers using tweezers and other therapy hand exercise tools. [B.] The Board being used as a “quick learn” but “high” level strategy game that brings fun and enjoyment to those that play as S3DTTT is a “winner” of a game!
Metaphorically speaking, there seems to be a strong chemical double bond between S3DTTT being a game and a therapy board. The strong double bond is not from polarity or electron configuration but from functionality, functioning as both a game and a therapy board! I really feel that there is so much help, healing and fun that can come from S3DTTT!

Deliverables:
1. The extended design of the “Size” of “Stackable 3D Tic Tac Toe”, S3DTTT. What would be the most popular and functional smaller size?
2. The extended design of different “materials” that are used in the construction of the game/therapy board. In addition, and as listed in the Objectives section, the combination configurations called “entire collective” game/therapy boards, needs a docking mechanism designed to lock the different version boards of S3DTTT in a straight line through the connected boards for continuous play.
3. Startup and advancement of writing different sections of a therapy textbook for the therapy board of “Stackable 3D Tic Tac Toe”.
4. Design how to setup tournament play and schedules using S3DTTT as a game with first, second, and third place trophies.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Carlton "Rich" McCracken Jr. 2 Stackable 3D Tic Tac Toe, a winner of a game and a helpful, healing therapy board! Gall, Oren 2 0 1 3 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Overview/Objectives:
This is the second Penn State Capstone Design project for the 2025 spring semester featuring “Stackable 3D Tic Tac Toe”, S3DTTT. As one reviews and examines “Stackable 3D Tic Tac Toe” it is seen that it has a twofold purpose, it is both a game and a therapy board. I really feel that there is so much help, healing and fun that can come from S3DTTT! This second project concerns the "Techie Side" of S3DTTT in adding computer, interface, code, and sensors to bring S3DTTT to a vibrant, digital screen life that can have data captured and recorded for review, reference, and play. This will allow S3DTTT to be used in multiple channels of communication to the users as patients, those supervising the therapy, and for those that are playing the game. The data and the game can hopefully be shared in the future over the internet. Overall, the project involves the creation of an app to allow the unit to connect to a computer or tablet to capture and collect a therapy patient’s data in completing various therapy exercises/tasks for later review and reference by therapists, nurses, and doctors. Many therapists have multiple patients at one time working on exercises/tasks and need a data collection system for each patient and each exercise. By comparing such informative patient data, the therapist can see if the patient is progressing, staying the same, or declining. The therapist can then gain a better understanding of how to treat their many patients. This project could advance therapeutic patient care to a much higher level and be more economical in the long run as well. In addition, since S3DTTT can be played for recreational purposes as well, the app should have the capability to track other activities such as the winner or loser or complex level or move.

Deliverables:
1. The startup and advancement of computer interface and programing to capture and collect a therapy patient’s data and also creating and establishing an index for the therapy patient. By collecting answers to survey questions and data from therapy exercises/tasks, the computer will analyze the generated data and give an index number which will tell the therapist the patient’s baseline, (where the patient is located in the established index). Once this index number/baseline of the patient has been generated, the established index table information will specify what exercises and how many repetitions are needed at present and a future exercise plan.
2. The startup and advancement of computer interface and programing to capture, collect, and monitor the game activities and give game alerts as to who won and who lost. This will be a real challenge as well! The winning and losing alerts could possibly be audio alerts or lighting alerts or both together. The most complex and difficult alert will be the loss for the player who has knocked over a tower of game pieces. Also, maybe even more difficult, alerting a player they have won when using one of the house rules, the diagonal rule of 75 degrees. This is my “Hail Mary Pass” rookie suggestion for a thought in how to possibly program code to accomplish these “win and lose” alerts. Each of the nine bolts will be projected on some type of background receptor screen and then monitored as a separate X and Y graph. With an X and Y axis, if there is a positive or negative slope greater than an angle that assures that the tower has fallen, a loss alert will be sounded or seen. For the diagonal rule, when three game pieces, (in the patent, called “Tubes), of the same color align with the slope of 75 degrees, a winner alert is implemented.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Center for Immersive Learning and Digital Innovation, Penn State University Automated Tracheostomy Suctioning System Medina, Scott 1 0 0 3 0 0 3 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project aims to develop an Automated Tracheostomy Suctioning System (ATSS) to enhance the safety, efficiency, and precision of tracheostomy care. The device will address critical clinical needs through advanced features, providing patients with a reliable and user-friendly solution while enabling clinicians to deliver personalized care. The system integrates state-of-the-art technology, including flexible suction catheters, depth control mechanisms, and real-time monitoring, to minimize airway trauma and improve patient outcomes.

Deliverables:

Device Structure and Components:

Flexible Suction Catheter: Medical-grade silicone or PVC material with adjustable diameters to suit diverse patient needs.
Depth Control Mechanism: Motorized precision control for safe and adjustable catheter insertion.
Closed-loop CO2 Monitoring: Integrated sensor for position verification, ensuring accurate catheter placement.
Pressure and Depth Sensors: Alerts for excessive insertion force, preventing tissue trauma.
Adjustable Suction Pressure: Feedback-regulated suction ranging from 50–150 mmHg for consistent performance.
Hypoxia Detection and Hemoglobin Sensor: Real-time oxygen and blood detection to prevent complications.
User Interface and Control Panel:

Digital touchscreen with customizable suction settings, monitoring alerts, and emergency manual override functionality.
Programmable suction intervals and real-time alerts for patients and clinicians.
Multi-mode operation (automated, manual, hybrid) and patient-specific suction profiles for personalized care.
Connectivity and Data Management:

WiFi/Bluetooth integration with ICU monitoring systems for remote oversight.
Data logging of suction events, depth, and pressure settings for quality assurance and clinical review.
Power and Durability:

Long-lasting primary battery with backup power for uninterrupted operation.
Biocompatible, sanitizable materials for safe and frequent usage in clinical settings.
Infection Control:

Disposable, single-use catheters and tubing to minimize infection risks.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Center for Immersive Learning and Digital Innovation, Penn State University Designing an Integrated Data Management Solution for Efficient Tracking and Reporting in Nursing Education Verbanec, Alan 0 0 2 1 0 3 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project aims to address inefficiencies in data management at the Ross and Carol Nese College of Nursing. The current system relies on disparate spreadsheets managed individually by faculty and staff, resulting in inconsistent reporting and inefficiencies in decision-making. The project involves designing a comprehensive data management solution that:

-Tracks students from their initial expression of interest in programs through their graduation.
-Streamlines teaching assignments to align faculty availability and expertise with course needs.
-Deliverables include a fully documented proposal for a functional data management system, a prototype or proof of concept demonstrating its core functionalities, and recommendations for its implementation within the College of Nursing.

This project provides students with the opportunity to tackle a real-world problem, leveraging skills in systems analysis, database design, and process improvement. The solution must be scalable, intuitive, and customizable to meet the specific needs of the College.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Center for Immersive Learning and Digital Innovation, Penn State University Enhancing Patient Safety through Mixed-Reality Guided Central Line Insertions Hylbert, Lyndsey 1 0 3 2 0 0 3 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Healthcare-associated infections pose a significant threat to patient safety, with alarming statistics indicating that one in thirty-one patients develop infections daily, leading to severe outcomes such as sepsis and high mortality rates. Central Line Associated Blood Stream Infections (CLABSI) are a critical concern in hospitals, exacerbated by the challenges posed by the COVID-19 pandemic. The urgent need for innovative solutions to prevent CLABSI and improve patient outcomes cannot be overstated. Central lines, while essential for patient care, also present risks. Our project focuses on leveraging mixed-reality technology to enhance the safety and efficacy of central line insertions. By integrating augmented reality, we aim to create a guided platform that assists novice clinicians in performing central line insertions with precision and reduced risk of infection. Why Choose This Project? 1. Real-World Impact: Address a critical healthcare challenge with direct implications for patient safety and quality of care. 2. Innovative Technology: Gain hands-on experience with cutting-edge mixed-reality technology in healthcare applications. 3. Interdisciplinary Collaboration: Collaborate with experts across healthcare, technology, and education to develop a holistic solution. 4. Professional Development: Enhance skills in project management, research methodology, and healthcare innovation, preparing for future career opportunities in healthcare technology and patient safety.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Center for Immersive Learning and Digital Innovation, Penn State University Enhancing Patient Safety through Remote-Controlled Robotics for Intravenous Administration Gall, Oren 3 0 3 2 0 0 1 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Healthcare-associated infections pose a significant threat, affecting one in thirty-one patients daily and leading to severe complications such as sepsis, which tragically claims the lives of over half of those affected. Central Line Associated Blood Stream Infections (CLABSI) are a critical concern, exacerbated by the challenges posed by the COVID-19 pandemic, which has drastically increased infection rates and strained hospital resources. Central lines, vital for patient care, paradoxically contribute to infections. Our project aims to innovate by integrating robotics to revolutionize intravenous administration, reducing the need for frequent nurse entry into ICU rooms and minimizing PPE usage. By enabling remote-controlled access to intravenous systems, we aim to mitigate infection risks associated with central lines and enhance patient safety. Why Choose This Project? 1. Real-World Impact: Address a critical healthcare challenge exacerbated by the COVID-19 pandemic with innovative robotics technology. 2. Cutting-Edge Technology: Gain hands-on experience with robotics, automation, and healthcare innovation, preparing for future careers at the intersection of engineering and medicine. 3. Interdisciplinary Collaboration: Work alongside experts in biomedical engineering, computer science, and healthcare to develop a solution with tangible benefits for patient safety and healthcare efficiency. 4. Professional Development: Enhance skills in project management, engineering design, and healthcare technology implementation, valuable for future academic and career pursuits.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Center for Immersive Learning and Digital Innovation, Penn State University Promoting Safe Tracheostomy Care through Multiplayer Virtual Reality Case Scenarios Verbanec, Alan 2 0 0 1 0 0 0 0 0 3 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Tracheostomy care presents significant challenges in healthcare, with high rates of adverse events, workforce shortages, and escalating healthcare costs exceeding $11 billion annually in the US alone. The complexity of inpatient and community-based tracheostomy care, coupled with the extensive training required for healthcare professionals, underscores the critical need for innovative solutions to improve patient safety, reduce complications, and ensure equitable access to high-quality care. Our project focuses on leveraging multiplayer virtual reality (VR) technology to enhance the training and competency of healthcare professionals in tracheostomy care. By immersing participants in realistic case scenarios, we aim to simulate complex patient care environments, including suctioning, stoma care, emergency responses, and patient monitoring. This immersive VR experience will enable healthcare teams to practice critical decision-making and procedural skills in a safe, controlled setting.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Center for Immersive Learning and Digital Innovation, Penn State University Robotic Dressing Site Monitoring Device for Early Detection of Central Line Infections Mahmoodi Takaghaj, Sanaz 2 0 3 3 0 0 1 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Healthcare-associated infections pose a significant threat, affecting one in thirty-one patients daily and contributing to high mortality rates due to conditions like sepsis. Central Line Associated Blood Stream Infections (CLABSI) are particularly concerning as they often arise from life-saving central lines, turning a critical intervention into a potential cause of death. The COVID-19 pandemic has exacerbated infection rates, making it imperative to innovate and prevent CLABSI to safeguard patient health and improve healthcare efficiency. Our project focuses on developing a robotic dressing site monitoring device aimed at early detection of infections associated with central lines. This innovative device will continuously monitor the insertion site for signs and symptoms of infection, promptly notifying nurses when predefined criteria indicative of infection are met. Early identification through automated monitoring can facilitate timely intervention, preventing CLABSI and improving patient outcomes.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Center for Immersive Learning and Digital Innovation, Penn State University Safer Tracheostomy Care through Mixed Reality Solutions for Tube Change Procedures Verbanec, Alan 2 0 0 1 0 0 0 0 0 3 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The care of patients with tracheostomies presents complex challenges, including high rates of adverse events, workforce shortages, and escalating healthcare costs exceeding $11 billion annually in the US. With over 100,000 tracheostomies performed each year, the demands for specialized care and training continue to rise, particularly in mitigating risks associated with tracheostomy tube changes—a critical procedure prone to complications. Our project focuses on leveraging mixed reality (MR) technology to enhance the safety and efficacy of tracheostomy tube change procedures. By merging virtual and augmented reality, we aim to simulate realistic scenarios that enable healthcare professionals to practice and refine their skills in a controlled environment. This innovative approach not only addresses training challenges but also aims to reduce adverse events, healthcare disparities, and overall costs associated with tracheostomy care. Why Choose This Project? 1. Innovative Healthcare Technology: Engage in cutting-edge MR technology to revolutionize tracheostomy care training and procedural safety, preparing for future advancements in healthcare technology. 2. Impactful Learning Experience: Gain hands-on experience in healthcare simulation, scenario design, and interdisciplinary collaboration, essential for careers in healthcare innovation and patient safety. 3. Global Health Impact: Contribute to reducing healthcare disparities and improving access to high-quality tracheostomy care through innovative educational solutions accessible to diverse healthcare settings. 4. Professional Development: Enhance skills in project management, research methodology, and technology implementation, valuable for advancing academic and professional goals in healthcare and biomedical engineering fields.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Cocoziello Institute of Real Estate Innovation Design of Origami-based Reconfigurable System for Sustianable and Resilient Buildings Mahmoodi Takaghaj, Sanaz 0 0 0 0 0 1 0 3 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This capstone project aims to using origami engineering to develop protective systems on buildings. This multidisciplinary project will have mentors from architecture, engineering design, mechanical engineering design, and structural engineering to develop novel solutions for adaptive systems from small scale prototyping, manufacturing/constructing origami specimens, instrumenting it with sensors and actuation (robotics and control), as well as conducting computational simulations for understanding wind performance, feedback control, and lifecycle environmental assessment. The deliverable for this project is a final prototype showcasing the capability of the proposed origami-based reconfigurable solution for protecting buildings against worst-case scenarios.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Cocoziello Institute of Real Estate Innovation Learning Factory Digital Twin Mittan, Paul 0 0 0 3 0 1 3 3 0 2 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The project goal will be to develop a digital twin of the Learning Factory spaces within the Engineering Design and Innovation (EDI) building that allows users to gain a better understanding of the real-time use and layout of the space, leveraging a 3D model and sensor data.  The team will first develop a digital twin (DT) plan that documents the DT goal and use case(s) by meeting with the project mentors and end users.  They will then explore the different data sources available and develop a prototype of the Learning Factory Digital Twin, leveraging a detailed 3D model in Revit for the EDI building.  The Digital Twin could be developed in a gaming platform, such as Unreal Engine or Unity, or using another digital twin solution platform.  The team should explore different options for prototype development.  Following the development of the prototype, the team should gain feedback from potential users, including shop supervisors, faculty, and students.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Cocoziello Institute of Real Estate Innovation Virtual Reality Training Program for Construction Robot Operation Zajac, Brian 0 0 2 1 0 0 0 0 0 3 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The construction industry is rapidly evolving with the integration of advanced robotics. To ensure that union workers remain relevant and capable of working alongside these new technologies, this project will develop a comprehensive VR training program. The training will simulate real-world scenarios, allowing workers to gain practical experience in a controlled, risk-free environment. The VR program will cover various aspects of robot operation, safety protocols, collaboration techniques, and troubleshooting.
The project aims to demonstrate VR training program designed to enhance the skills of union workers in operating and collaborating with construction robots. Key deliverables include comprehensive training flowcharts, and interactive VR modules covering various aspects of robot operation and safety protocols. A working prototype of the VR training program will be developed. The expected outcomes are an immersive and practical learning experience that improves safety and efficiency in the workforce, along with a detailed report and presentation to showcase the project's development and effectiveness. This initiative promises to create a significant impact on the construction industry by preparing workers for the evolving technological landscape.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Cocoziello Institute of Real State Innovation Design of Resilient, Economical, Affordable and Multidimensional (DREAM) Housing Solutions in Rural Appalachia Mahmoodi Takaghaj, Sanaz 0 0 0 0 0 1 0 3 0 0 2 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Overview
Rural Appalachia faces significant challenges in recovery exacerbated by frequent climate-related disasters. This project addresses these issues by Designing a Resilient, Economical, Appropriate and Multidimensional (DREAM) Housing Program that integrates disaster resilience, community-centric design, and sustainable development. This project also involves a collaborative process with local stakeholders to create housing solutions that are hazard-resistant, culturally appropriate, and economically feasible. The project will utilize human-centered design principles and systems thinking, focusing on empathy, defining needs, ideating solutions, prototyping, and testing. This project will engage with local communities and leverage partnerships with organizations such as Fahe (network of 50+ nonprofits in rural Appalachia region) to identify opportunities for design to establish problem statement and subsequent sustainable project solutions to this complex problem.
Deliverables
This project will design innovative housing prototypes that are resilient to climate impacts and adaptable to local needs and extreme users in rural communities. The anticipated outcomes include improved housing stability, reduced displacement, and enhanced recovery ecosystem and disaster preparedness.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Custom Created LLC. T.H.E. Tool Wang, Chao-Yang 0 0 0 0 0 3 0 0 0 2 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

T.H.E. Team II- Team will focus on working with past team (Fall 2024) prototype designs to finalize base design.

Background of design: Invasive species globally have been estimated to cost $1.288 trillion over the past 50 years (Zenni, R.D. et al. 2021). These pests come in various forms such as mammals, insects, plants, and reptiles. Plants are a type of invasive species that can be directly addressed without the need of following/baiting as they are sedentary. T.H.E. Tool is designed with a focus on terrestrial invasive plant removal. Having the ability to remove these destructive species manually, we can follow integrated-pest management (IPM) suggestions of mechanical removal without the need for chemical interventions. The current market for invasive plant pullers are typically bulky and not the best solution for aging landowners, who on average are 57 in the state of Pennsylvania (PSU Resources for Woodland Owners). The need for a tool that is easy to use and able to help provide other uses such as planting of native species is ideal to increase the ability of land owners/managers to properly work their land without having to pay others or resort to expensive and environmental unfriendly interventions. This tool will incorporate experience with mechanical invasive species removal and a continual “need” for a device that can make the work of removal less physically taxing so one can work longer and remove more invasive plants in less time.

Customer segment(s): Private land owners, land managers, local, state, and federal land management organizations

Target species: Japanese barberry (Berberis thunbergii), European barberry(Berberis vulgaris), multi-flora rose (Rosa multiflora) bush honeysuckle (Lonicera spp.), autumn olive (Elaeagnus umbellata), privet (Lingustrum spp.), burning bush (Euonymus alatus)

Target size: 12”-36” height, ¼”-1” diameter, 1-5 years old

Estimated price: 80$ for base, 30$ for weed puller attachment

Deliverables: Base of tool- This will provide a lightweight, collapsible foundation to use with multiple attachments.

Invasive puller attachment (The Claw) - This attachment will slide into the bottom of T.H.E. Tool base and provide a unique opportunity to remove multi-stem invasive forest plants.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Dana Incorporated AI and Machine Learning System for Gear Mesh Pattern Analysis Gall, Oren 0 0 1 2 0 0 3 0 0 3 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Problem Statement:
Gear pattern operations lack the ability to automatically detect gear pattern alignment causing Noise, Vibration or Harshness out of tolerance conditions.

Benefits:
Reduce rework due to Noise Vibration Harshness (NVH) tester fallout
Eliminate the need for the operator to review images at station
Reduce premature failure and warranty claims

Project Requirements:
Dana to provide 10 (minimum) master sample images for basis of comparison
Dana to provide 1000 (minimum) images for use with analysis to build detection system
Automated method to check gear mesh pattern against master images
Artificial Intelligence and machine learning related
Applicable to the following manufacturing facilities:
Toledo, Dry Ridge, Fort Wayne (requires vision system), Columbia

Project Deliverables:
Base scope is limited to operator decision (Pass/Fail) support at Op200 Gear Pattern Verification operation.
Create a simple Graphical User Interface for use on a tablet/PC with the following functions:
User ability to select multiple files to ingest as “master” good images and train the system
Ability to analyze images against the master data set. Images will be generated by the operation
Provide a summary report listing all checked files, with the status of Pass or Fail
Provide functionality to export the results to CSV file, including pertinent fields (Plant, Operation #, Time stamp, serial #, Pass/Fail, Failure reason/mode)

Stretch targets:
Provide functionality to define and categorize different failure modes when they are detected
Provide capability to search/filter for specific failure modes that are detected by the system
Provide data analytics functionality to provide data trending, pareto charts by failure mode type
Provide functionality to allow for additional machines/operations to be added to the system.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Dana Incorporated Multi-body dynamics in Vehicle Analysis - SJTU Global Project Neal, Gary 0 0 0 0 0 0 0 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Dana provides several typical operating conditions for a certain off-highway engineering vehicle, and the students will complete the analysis of the force model on the axle under these conditions. For example, under different load conditions, working speeds, and environmental temperatures (such as a typical Y cycle condition), establish the force models for various transmission components of the axle. Dynamically simulate the mechanical movement process and the interactions between different parts of the machinery during this process. Conduct analyses such as dynamic load factor distribution and braking distance.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Department of Energy and Mineral Engineering Designing Solar Systems for Specific Customer Needs Toraman, Hilal 0 0 0 0 0 0 2 1 0 0 3 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The project will involve a site visit to inspect or assess the suitability of the construction site (rooftop) identified by the customer for solar installation (i.e. site analysis for the prospective solar PV installations). The student team will have the unique opportunity to apply relevant solar skills/knowledge and use leading industry tools/software (HelioScope, Aurora Solar & System Advisor Model) to enable successful solar system design. The team will come up with a development plan for the project, assessing records, site plans, and other maps/documents that clarify which jurisdiction has authority over land development on a site. The team will also assess what forms of development are allowed in this zoning district or determine whether special or conditional use permits or re-zoning is required. The team will also perform a financial analysis of the project considering federal tax incentives (credits and accelerated depreciation) available for solar PV and other renewable projects.
Desired deliverables: Final report and oral presentation explaining the conceptual design, development plan, and financial analysis.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
DOMINO’S PIZZA LLC Inbound Logistics Forecasting Tool by Product, by Origin/Destination pair. Verbanec, Alan 0 0 0 1 0 0 0 0 0 2 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Create a tool to forecast logistics utilization (cube and weight) and lane cost utilizing product demand, shipping conveyance, and ship unit packaging. Close data gaps around missing IB shipping dimensional information. Identify opportunities to reconfigure ship units to drive decreased transportation. Enable plan vs budget vs actual cost by product and/or by OD pair at a cost per unit or cost per lb basis.

Tool should be designed in a way to consume data and update no less than weekly. Ideally tool can assign cost down to the item.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Drucker Diagnostics Refrigerated Centrifuge Performance Requirements Wang, Chao-Yang 0 0 0 0 0 0 0 0 2 3 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project involves identifying the cooling requirements for a refrigerated centrifuge, which is essential in the healthcare industry for preparing preanalytic blood samples used in diagnostic testing. Currently, Drucker Diagnostics does not offer refrigerated centrifuges but aims to develop refrigerated versions of two key non-refrigerated models.

The project consists of two phases:
1. Cooling Power Estimation: Determine the cooling power (in watts) needed to maintain the rotor chambers at a target temperature while the centrifuge is in operation. This phase will rely on both theoretical calculations and empirical data, including measurements of airflow, power consumption, and temperature.
2. System Research and Recommendation: Investigate potential equipment, methods, and systems capable of delivering the required cooling power. The goal is to recommend suitable systems for integration into the centrifuge design.

Completion of these phases will guide the development and eventual release of refrigerated centrifuge models. Note testing with blood samples is NOT required for this project. All testing can be completed with water as representative fluid to fill tubes and disposables.

Centrifuge 2: Dash Flex 6 (primary)
- Maximum speed: 5300 rpm
- Maximum load: 6 x 10mL tubes
- Minimum required rotor chamber temperature: -10°C
Centrifuge 1: Boost 4+ Max (secondary is time permits)
- Maximum speed: 4000 rpm
- Maximum load: 4 x 140 gram disposables
- Minimum required rotor chamber temperature: -10°C
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Duraloy Technologies, Inc. Mobile Workstation for Portable Laser Engraver Zajac, Brian 0 0 0 0 0 0 3 0 0 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

In early fall Duraloy Technologies purchased a SFX 30W portable laser engraving machine to increase part traceability. Duraloy would like to assemble a capstone team to design, engineer and build a mobile platform for this unit.

1. The Laser would need to be secured on the unit, allowing for horizontal and vertical adjustment
2. Laser Power unit will need to be secured to the cart while allowing the operator access to the touch screen, charging ports and USB Ports.
3. The cart will need to have a 120V power source attached to the cart that can be plugged into nearby outlets.
4. Laser Cone will need to be re-designed, current design is square. New cone design will need to be crescent shaped to allow etching on piping and round pieces.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Echogen Power Systems (DE), Inc. Additive manufacturing technology development for large-scale heat exchangers Wang, Chao-Yang 0 0 0 0 0 0 0 0 0 2 3 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Many power conversion and energy storage systems use a large number of heat exchangers, which are critical for their performance and make up a significant amount of the system cost and size. The most advanced energy systems in development are more dependent than ever on these key components. However, the manufacturing technology used for these systems was developed in the 1970's and 1980's, with little advancement since then.

Additive manufacturing offers a new way to design and build heat exchangers, but its use to date has focused on relatively small scale designs. The unique challenges posed by the scale of power conversion and energy storage systems have thus far been unable to be met by additive manufacturing processes. However, in the last few years, advances in AM technology have potentially enabled large-scale heat exchangers to be manufactured in a hybrid approach that takes advantage of both traditional and AM techniques.

In this project, the team will conduct a survey of the latest in AM technology with the assistance of Echogen and the PSU/3D Systems CIMP-3D collaboration, use a combination of classical heat transfer and fluid mechanical correlations to create a conceptual design of a heat exchanger core that can uniquely be manufactured through AM methods, and build a coupon-scale heat exchanger core that can provide validation of the conceptual design by subscale testing.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Eriez Manufacturing Co. Real-Time Measurement of Product Quality in Food Processing Lines Zajac, Brian 3 0 3 0 0 0 1 0 0 2 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This senior capstone collaboration will be a short-term project between Eriez Manufacturing and Penn State University’s Electrical Engineering department intended for the Spring 2025 semester. The objective of this project includes surveying and evaluating quality monitoring sensors (Process Analytics) that exist in today’s food and beverage industries. Process Analytical Measurements are a necessity in these industries to monitor and maintain production consistency and the quality of food production. Food safety and quality management not only impacts human health directly but can also affect manufacturing efficiencies and production yield rates, ultimately impacting the US economy [1]. As such, online, real-time measurements and monitoring of various parameters affecting production recipes in food industries becomes increasingly important.

1st Deliverable: Providing a summary of various quality monitoring sensors being used in today’s market. This will include summarizing the measurement principles, the communication protocols (Fieldbus, High Speed Industry Bus, HART Communication Protocol, IO Link, Ethernet/IP, etc.), the Inputs/Outputs for each sensor and their specific applications, not limited to the following:

1. Beverage applications [2,3]:
a) Dissolved O2 sensors
b) CO2 sensors
c) Turbidity sensors
d) pH sensors
e) Conductivity sensors
f) Oxidation Reduction Potential sensors

2. Packaged food applications [4]:
a) Time-Temperature Indicators (TTI)
b) Freshness Indicators (FI)
c) Leak Indicators (LI)
d) pH Indicators (PHI)

2nd Deliverable: Prototype development for real-time data collection of signals from a subset of surveyed sensors. This effort will enable a real-time mechanism to collect data for various products from different sensors. A preliminary analysis to prove the feasibility of this prototype will also be a required deliverable for this project.

[1] Cozzolino, D., 2022. Sensors for the Food Industry: An Introduction.
[2] https://www.mt.com/us/en/home/products/Process-Analytics.html
[3] Dodero, A., Escher, A., Bertucci, S., Castellano, M. and Lova, P., 2021. Intelligent packaging for real-time monitoring of food-quality: Current and future developments. Applied Sciences, 11(8), p.3532.
[4] Ma, Y., Yang, W., Xia, Y., Xue, W., Wu, H., Li, Z., Zhang, F., Qiu, B. and Fu, C., 2022. Properties and applications of intelligent packaging indicators for food spoilage. Membranes, 12(5), p.477.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Flowserve US Inc Hydraulic Submergence Development Banyay, Greg 0 0 0 0 0 0 0 0 0 2 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

In their most basic forms, pumps are used to convert kinetic energy to static pressure. They are used to move a liquid from one place to another. Customer limitations often require pumps to be mounted in sub-optimal or non-traditional configurations. In this project, you will investigate, characterize and visualize the fluid behavior when the hydraulic is mounted non-traditionally (toward the free-surface). This project aims to comprehensively analyze the formation and behavior of vortices in a hydraulic system where an impeller is mounted some distance below the free surface of the fluid. You will develop a comprehensive test plan to evaluate different speeds, hydraulics, fluid viscosities, etc. A test rig has been developed previously by PSU and our team feels this test rig can serve as the basis for thorough hydraulic verification testing and mitigation provisions. Once the vortex behavior is characterized by the team, they will develop “swirl-break” equipment to be mounted on the rig. Swirl breaks are designed to mitigate or minimize bubble or vortex creation.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Fox Rotating Equipment Solutions Adjustable Diffuser Wall Geometry for Turbomachinery Testing Wang, Chao-Yang 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Among the many components in a centrifugal compressor, the diffuser is often regarded as the second most important, only behind the impeller that drives the flow through the machine. The diffuser is immediately downstream of the impeller (see figure), which accepts the incoming high kinetic energy gas and begins a conversion to static pressure for a desired application. Depending on the impeller operating conditions and compressor case sizing, the dimensions of a given diffuser can vary in many ways. Different diffuser types can be seen in the figure, such as (a) parallel wall, (b) pinched, and (c) tapered. All of which could have desirable aerodynamic improvements for different machine configurations.

While one wall of the diffuser does not change much from test to test, the shroud side (left side wall in the figure) does often change. Couple the frequent costs to replace the shroud side diffuser with it being a long-lead item for manufacturing, and expenses quickly rise over the course of a year of testing. Developing a rig-fixed, movable geometry to accommodate changes to the shroud side diffuser could eliminate long part lead time, increase testing frequency, and decrease testing costs.

The engineering team at FOX would be excited to sponsor a team to conduct preliminary development of a movable diffuser wall insert for the test rig. Desirable project outcomes to work towards include:
(1) conceptual CAD modelling of the wall insert and actuation equipment and
(2) a prototype demonstrator capable of conforming to a specified diffuser wall profile while preserving instrumentation requirements.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Goodwill Keystone Area Feasibility Analysis of Electric Vehicle Integration into Class 8 Truck Routes Zajac, Brian 0 0 0 0 0 0 0 2 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The transportation sector, particularly freight logistics, is one of the largest contributors to greenhouse gas emissions, prompting an urgent need for cleaner alternatives. Class 8 trucks, essential for long-haul freight, are heavily reliant on diesel, which significantly contributes to pollution. This capstone project aims to analyze the feasibility of integrating electric vehicles (EVs) into Class 8 truck routes, with a focus on route efficiency, the current range of EVs, potential return on investment (ROI), and the future outlook of emerging technologies.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Hatch Optimized Natural Convection Heat Removal System Wang, Chao-Yang 0 0 0 0 0 3 3 0 0 0 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Typically, the most efficient method for heat removal using air as the cooling medium is a forced air system (using a fan or other mechanical device). However, for systems that require fully passive operation, a natural convection heat removal system is the only option.

Hatch originally sponsored two teams for this topic in Spring of 2024, and it encountered some challenges. These challenges will be described to the new project team and the goal will be to strategize ways to overcome these items and fully complete the objective. The design should first be developed using hand calculations, then confirmed using analysis (such as CFD), and finally proven with a scale model test.

Overall, the project will be focused on proper mechanical design with the need to optimize instrumentation use in the scale model test.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
InkSphere InkSphere Marker Pen Smith, Tahira Reid 0 0 0 0 0 1 0 0 0 0 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

A redesign of the dry erase marker using already proven solutions from the rollerball pen/ballpoint pen specifically designed for whiteboards, offering precision, durability, and eco-friendliness. Ensuring strokes are smudge-free, the marker has a long-lasting use life and enhances user experience in professional, educational, and creative settings.

- Longevity:
One of the main issues with dry erase markers is their lack of longevity. According to our research, a frequently used dry erase marker will only last 3-4 weeks, with some lasting as little as 1 week. Even with the cap sealed tightly, the marker will still dry out because it is not airtight. Air can pass through the porous surface of the felt tip, eventually causing the ink cartridge to dry out.

- Precision:
The most popular shape of the tip for dry erase markers is the chiseled tip. The issue with the chiseled tip is the unevenness in thickness. Therefore, if you go up and down, you will get a thin line, but if you go side by side, you will get a thick line. This leads to users having to change directions by rotating the marker.

- Ergonomics:
The traditional dry erase marker is just a cylinder, with little to no thought for user comfortability. Our customer research says we aim to solve this by introducing a gel grip that can form to the grip of the user.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
ISSIP.org (The International Society of Service Innovation Professionals) AI for ISSIP Onboarding Workflow: Design and Evaluation Zajac, Brian 0 0 0 2 0 0 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Building on the work of three previous PSU Learning Factory teams that explored the use of new AI tools to help ISSIP volunteers create content (service system innovation historic case study playbook), scale performance (AI digital twin), and accelerate onboarding (Guidebook for Service Roles), this time the student team will focus on using AI to transform the critical one-hour of manual onboarding into a partial self-service and full self-service offering to new ISSIP participants and volunteers.

The one hour on-boarding manual design includes: (1) learning service system innovation concepts, (2) learning the ISSIP constellations of platforms, and (3) learning the ISSIP annual calendar of programs and events to participate, contribute, and develop as a service innovation professional.

A pre-test and post-test will need to be designed with the help of generative AI.

The workflow will have to be optimized.

Qualitative and quantitative measures of the improved workflow will need to be created and evaluated.

Five Key Deliverables:(1) ISSIP One-Hour Onboarding Design (workflow for manual and self-service), (2) Whitepaper, (3) Presentation, (4) Script, (5) Final Recorded Presentation.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
KC Consolidated LLC Custom Watchband Clasp Kimel, Allen 0 0 0 0 0 1 0 0 0 0 2 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Capstone Project: Redesigning the Adjustable Watchband Clasp

Project Overview
Our company currently sells an adjustable watchband with a basic clasp design. While functional, this clasp is also available from other manufacturers, and we believe there's an opportunity to innovate and differentiate our product in the market. The goal of this capstone project is to redesign the clasp to be sleeker, more secure, and potentially patentable. Students will be tasked with researching, designing, prototyping, and testing a new clasp that not only enhances the aesthetic appeal and functionality but also meets the criteria for patent protection and mass production feasibility.

The redesigned clasp should provide a stronger and more secure connection while maintaining or improving the adjustability and comfort of the existing band. It should stand out in the marketplace, offering both a unique design and a strong competitive advantage. Students will need to consider materials, manufacturing processes, user experience, and potential intellectual property protections throughout the project.

Project Deliverables List
1. Project Initiation and Planning
Kick-off Meeting: A session to brief students on the current clasp design, its limitations, and the expectations for the new design.
Project Plan: A document outlining:
Project Objectives: Clear goals for a sleek design, stronger connection, and patentability.
Timeline: Milestones and deadlines for each phase.
Roles & Responsibilities: Task distribution within the group.
Risk Management: Potential obstacles and mitigation strategies.

2. Research and Analysis
Competitive Analysis Report: A review of similar clasp designs available in the market, analyzing their strengths, weaknesses, and opportunities for differentiation.
Technical Research: Investigating materials, manufacturing processes, and the engineering principles behind adjustable watchbands and clasps.
Patent Search and Analysis: A report identifying existing patents for similar designs and highlighting opportunities for innovation and patentability.
User Feedback: Gathering customer insights (via surveys or interviews) to understand desired features and pain points in existing clasp designs.

3. Design Development
Initial Concept Designs: Preliminary hand-drawn sketches or digital renders of potential redesigns with a focus on aesthetics and usability.
Design Brief: A document describing:
Design goals (e.g., sleekness, functionality, durability)
Key features (e.g., adjustability, ease of use, security)
Material considerations
Concept Review & Feedback: Presenting the initial concepts to stakeholders for feedback and refinement.

4. Detailed Design and Engineering
3D CAD Models: High-quality, detailed CAD models of the selected design(s), including:
Full assembly views
Key components (e.g., latch, hinge, locking mechanism)
Material specifications
Prototyping Plan: A document detailing the process for building a prototype, including materials, tools, and techniques.
Engineering Calculations: Stress tests, simulations, and material analysis to ensure durability and performance under load.
Manufacturing Considerations: Documentation of production feasibility, including potential techniques (e.g., injection molding, CNC machining) and tooling requirements.

5. Prototype Development
Prototype Creation: Development of a physical working prototype of the new clasp.
Testing and Validation Report: Documenting the results of prototype testing for:
Strength and durability (e.g., load-bearing, wear and tear)
Usability (e.g., ease of use, comfort, and security)
Adjustability and compatibility with various wrist sizes
Iterative Improvements: Making design adjustments based on testing feedback to improve functionality and durability.

6. Patent Application
Patentability Report: An analysis of the clasp’s originality, identifying novel features that could be patented.
Patent Draft: A detailed description of the clasp design, including:
Claims outlining its unique features.
Drawings and diagrams, including exploded views.
Patent Search Summary: A review confirming that the design does not infringe on existing patents.
Patent Filing: Assistance in preparing a provisional patent application (optional, depending on the company’s strategy).

7. Final Design Presentation
Final Design Review: A comprehensive presentation to stakeholders that includes:
3D renderings or animations showing the clasp in action
A demonstration of the clasp’s functionality (possibly using a physical prototype)
Technical specifications and key advantages over existing designs
User Experience Demonstration: A video or live demonstration illustrating the clasp's usability, security, and ease of adjustment.

8. Documentation and Handover
Design Documentation: A complete technical packet, including:
CAD models and drawings
Material specifications
Manufacturing instructions
Testing results and validation reports
Final Report: A comprehensive project report that summarizes:
Project goals and outcomes
Challenges faced and how they were overcome
Design rationale and key decisions made
Patent and market research findings
Manufacturing & Scaling Considerations: A report detailing potential challenges for mass production and recommendations for scaling.

9. Final Submission
Project Portfolio: A well-organized collection of all deliverables, including sketches, CAD files, technical documentation, and final designs.
Presentation Deck: A concise PowerPoint presentation summarizing the project and its key outcomes.
Reflection and Lessons Learned: A brief report reflecting on the project process, including challenges and key learnings from the experience.
Optional Bonus Deliverables (for Additional Impact)
Market Feasibility Study: An analysis of the potential market for the redesigned clasp, considering target demographics, competitors, and price points.
Branding and Marketing Concept: A set of promotional materials or concepts to support the product's market launch.
Sustainability Considerations: Suggestions for environmentally friendly materials or manufacturing processes that could be incorporated into the clasp design.

This deliverables list provides a structured, detailed path for students to follow throughout the redesign project, ensuring they meet both the technical and business goals of the company while working toward a patentable, commercially viable product.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Lockheed Martin Mobile UAV Battery Charging & Health Monitoring Mittan, Paul 0 0 3 0 0 3 1 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Supporting UAV demonstrator flight tests with multiple UAVs at a variety of locations creates logistical challenges for the support team. Managing the power sources, LiPo batteries, is a key interest for the demonstration team as a successful flight test requires multiple batteries and multiple charge cycles. The objective of this project is to design and develop a mobile platform to manage the batteries and provide monitoring functions to promote safe charging/discharging practices. The mobile platform will contain the required equipment to safely charge and discharge batteries. Students will develop a system to identify/catalog batteries, track their usage cycle, and monitor the health of the batteries in rotation (8-10 units). Additional sensors, thermal or optical, should be used to alert operators of any abnormalities. Data will be displayed on a digital screen and also be exportable.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Logitech Europe SA PCB-less Computer Mouse Design Innovation Cubanski, Dave 0 0 0 0 0 0 1 0 0 0 3 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Design and prototype a more sustainable computer mouse that replaces traditional PCB with direct circuit printing technology.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Lyndsey Hylbert Assistive Transport Device for Older Child Medina, Scott 1 0 0 0 0 0 0 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

A small, lightweight transport device is needed to assist a 10yo Autistic child move through an airport. Traditional strollers are for smaller, lighter children, and other wagon options are too heavy and large for airport security. A device is needed to aid in moving the child through the airport, particularly after overnight flights when fatigued. The child can walk, but has very limited stamina. The device should meet airplane carry-on requirements, support up to 200lb, be quickly assembled/disassembled, easily steered and pushed by the caregiver, and weigh under 25lbs.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
McFarlane Mfg. Co, Inc. Agricultural equipment fail-safe component engineering & lab test validation. Wang, Chao-Yang 0 0 0 0 0 2 0 0 0 0 3 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Agricultural equipment fail-safe component lab test validation. Review CAD model of initial concept provided by sponsor company, perform FEA with prediction shared by sponsor, develop CAD model iterations from initially provided, evaluate/challenge initial assumptions/load-cases, then perform testing on samples (potentially produced by sponsor). Develop impact and fatigue test with fixtures you design using available equipment & instruments in Learning Factory.

Provide design for physical testing for subsequent field validation by the sponsor.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Mechatronics Research Lab Two-Axis Solar Panel Sun Tracking with One Actuator Mittan, Paul 0 0 0 0 0 0 2 0 3 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Two-axis tracking for solar panels aims to maximize energy capture by continuously aligning the panels with the sun's position throughout the day and across seasons. Unlike single-axis trackers, which only follow the sun's movement from east to west, two-axis trackers adjust both the horizontal and vertical angles. This allows the panels to maintain an optimal angle to the sun, increasing efficiency and energy output. The primary objectives are to enhance the overall performance of solar power systems, reduce the levelized cost of electricity, and improve the return on investment by capturing more sunlight and converting it into electricity more effectively. The cost of a second actuator to provide seasonal elevation tracking is often prohibitively high. In this project, two axis (daily azimuth and seasonal elevation) tracking is sought using only one actuator. The final deliverable is a tabletop demonstrator of the proposed design.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Microversal LLC Artificial mouth flow cells for bacterial transplants Medina, Scott 1 0 0 0 0 0 0 0 0 2 3 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project is to make improvements to a patent-pending 3-D printed flow cell that is used to grow bacterial biofilms from the human mouth. The reuseable flow cell mimics a human mouth and uses a confined space made from autoclave-able materials, hydroxyapatite discs that mimic human tooth enamel, and a flow rate of human saliva media that mimics the amount of saliva produced in the human mouth. Bacterial biofilms collected from donors are injected into the system to grow so that they can then be tested for safety, modified for efficacy, or studied for the purposes of oral microbiome transplantation. Microversal LLC utilizes these biofilms to grow donor dental plaque for the development of new preventative treatments for dental decay (cavities) and periodontal disease. Microversal LLC would like to work with a team that can develop improvements into the flow cell that include increasing the size of the growth chamber by at least 6x its current size and output and allowing the flow cell to be opened and accessed in real time while the flow cell is running. A successful project will produce a new flow cell that will be used in commercial production of biofilms by Microbersal LLC.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
MilTech (Montana State University) Next Generation EMP Survivable Equipment Case Kimel, Allen 0 0 0 0 0 2 0 0 0 3 1 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Objective: Design, prototype, and test a low cost, lightweight, transportable, electronic pulse protection survivable equipment case.

Overview: This project includes two parts.

Part I: Current Equipment Case. The project requirement is to 3D scan, review, and recommend improvements to the design of a specific equipment case used to transport electronic equipment in austere environments.

Part II. Next Generation Custom Case. The project requirement is to design, prototype, and test a next generation custom case. Priority for the design is to minimize weight, reduce manufacturing cost, ensure electronic pulse protection survivability, and to consider transportability in an austere environment. The inclusion of next generation materials is highly encouraged.

Deliverables:
(1) custom designed electronic pulse protection survivable equipment case to transport defined military equipment. (Dimensions for equipment to be provided at kickoff)
(1) written report (electronically delivered) covering the following:
(a) Executive Summary
(b) Current Case: design, weight, material, recommended design or manufacturing improvements.
(c) Custom Designed Case: design, material, weight, manufacturability, estimated cost to manufacture (qty 10 and qty 1,000), estimated lead time, EMP survivability, test event(s), test results, issues.
(d) Alternative Materials and Additive Manufacturing: next generation materials and ability to repair or manufacture in an austere environment.
(e) Recommendations.
(1) Power Point presentation covering information provided in written report. Include photos documenting the design process, testing event(s), and final result.
(1) set of current case 3D scans and design files.
(1) set of custom case 3D scans and design files.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
MSA Worldwide, LLC Low Power Infrastructure Free Location Tracking Gall, Oren 0 0 1 3 0 0 2 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Our portable gas detection products need a battery-life of 2 or more shifts but also require a more accurate location to send help when an adverse event happens!

This project will focus on exploring innovative ways to balance power efficiency with location accuracy in portable devices. Specifically, it aims to achieve these goals by:

-Exploring alternative GNSS operational modes to balance power consumption and location accuracy.

-Identifying supplementary data sources, algorithms, or services to improve location accuracy and optimize power usage. Potential solutions include vendor-specific innovations (e.g., u-blox CloudLocate) and third-party services like AWS Location Services.

-Investigating designs for future product iterations that incorporate low-power, high-accuracy technologies.

The outcome of this study will help shape the next generation of location-enabled portable devices, focusing on optimized battery life and enhanced accuracy.

Expected Deliverables:

-A clear evaluation process that would be used to evaluate the hypothetical solutions. These evaluations will be used as solutions are proposed.

-A short list (2-5) of options that could be evaluated. These solutions must be infrastructure free.
Examples:

Explore different operational modes of u-blox GNSS modules, comparing the trade-offs between accuracy and battery usage.

Investigate additional data sources and enabling technologies, such as u-blox CloudLocate and AWS Location Services, to enhance power efficiency and location accuracy.

-Design, prototype, and evaluate at least one of the shortlist items.

-A recommendation for further exploration and/or a summary of shortcomings from evaluated solutions.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Naval Surface Warfare Center - Dahlgren Division Rugged Electronics Enclosure Banyay, Greg 0 0 0 0 0 0 0 0 2 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project will design a rugged enclosure to house control electronics. The design will need to operate in harsh environments and must be able to withstand extremes of temperature, shock, and vibration. It must also protect the the components from overheating. Details of the components that must be accommodated will be a given (e.g. waste heat values, operating temperature limits, etc), as will the ambient conditions, and basic size constraint.

Desired deliverables:
Design that meets requirements while considering thermal, weight, and cost optimization.
Thermal analysis of the cooling solution(s) used.
Presentation explaining the design.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Naval Surface Warfare Center Dahlgren Division Distributed Angle-of-Arrival and Ranging Network (DAARN) Cubanski, Dave 0 0 2 3 0 0 1 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Statement of Work:
Students will design and develop a prototype positioning system utilizing software-defined radio (SDR) and LoRa-based ranging technology for measuring angle-of-arrival (AoA) and range between multiple platforms using two-antenna arrays. Students are expected to gain knowledge and experience in the areas of Electromagnetics, Radio Frequency (RF) ranging technology, SDR programming, AoA signal processing, and antenna array design.

Learning Objectives:
1. Identify, formulate, and solve complex engineering problems by applying principles of engineering, science, and mathematics.
2. Apply engineering design to produce solutions that meet specified needs with consideration of public health, safety, and welfare, as well as global, cultural, social, environmental, and economic factors.
3. Communicate effectively with a range of audiences. Review and revise written and oral communication with peer and instructor critique.
4. Recognize ethical and professional responsibilities in engineering situations and make informed judgments, which must consider the impact of engineering solutions in global, economic, environmental, and societal contexts.
5. Function effectively on a team whose members together provide leadership, create a collaborative and inclusive environment, establish goals, plan tasks, and meet objectives.
6. Develop and conduct appropriate experimentation, analyze and interpret data, and use engineering judgment to draw conclusions.
7. Acquire and apply new knowledge as needed, using appropriate learning strategies.

Deliverables:
1. Market Survey and Feasibility Study
2. System Design Document
3. Engineering Drawing
4. Test Plan
5. Working Prototype
6. Technical Report
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Penn State University ASME e-Human-Powered Vehicle Neal, Gary 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The goal of this project is to design and build a vehicle for entry into the ASME human-powered vehicle competition. For the first time in 2022, the competition rules were significantly altered to allow electric pedal-assist vehicles. The capstone team is responsible for either significantly altering the previous year's vehicle platform or designing and building their own vehicle from the ground up. Deliverables include an operable vehicle, a description of the innovation over previous team's designs, and video demonstrations of several safety tests. Safety tests include roll over, turning, and breaking distance.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Penn State University Design of a printer farm for real-time energy monitoring and control Zajac, Brian 0 0 0 2 0 0 0 0 0 1 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The goal of the project is to design and develop an automated, energy-efficient printer farm that consists of a system of 3D printers, such as the Prusa i3, Creality CR-30, and/or Bambu Lab P1S. The students will begin by familiarizing themselves with the different printer capabilities. Then, students will identify a framework to gather, store, and analyze run-time printer data using either a local or cloud repository. This repository should enable detailed tracking of processed jobs, energy consumption, and other system parameters. Students will build an interface that visualizes the jobs, printers, and energy cost in the system. Real-time energy cost data and grid information should be incorporated in the visualization interface. Then, students will develop an optimization framework to dynamically adapt printer schedules to new jobs orders and changes in the energy cost. Finally, students will need to integrate the printers and the developed framework in one system (printer farm). As part of the project, students may need to build and integrate further automation capabilities in the system to allow for automated part removal, spool changing, and other capabilities to increase the automation capabilities of the printer farm.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Penn State University Modelling a Directed Energy Deposition Additive Manufacturing Process Zajac, Brian 0 0 0 2 0 0 0 0 0 1 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

In this project, students will explore the intersection of image processing and predictive modeling within the context of Directed Energy Deposition (DED) Additive Manufacturing (AM). The primary task involves analyzing images of deposition profiles to automatically measure the width and height of deposits under varying laser power and scanning velocities. These measurements will then be used to develop a predictive model, which could be AI-based or utilize other modeling techniques, to forecast the deposited dimensions. This project aims to enhance understanding of DED AM processes and improve the accuracy of deposition predictions, contributing to advancements in manufacturing technology.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Penn State University Opera Theatre Modular Set Design for Opera Productions in a Recital Hall Smith, Tahira Reid 0 0 0 0 0 1 0 0 2 0 3 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Project Description: This project aims to develop a long-term, sustainable, and modular set design that transforms a traditional recital hall into a versatile space suitable for staged opera productions. This specific design would serve the beautiful Penn State University School of Music Recital Hall. Due to the recital hall’s excellent acoustics for unamplified music, it is an ideal venue for opera, which traditionally does not utilize amplification. However, the hall lacks key features of a typical opera theater, such as a pit and wings. This project will address these limitations by designing a modular set that allows for flexible staging while supporting operatic acoustics and stage dynamics.

Project Objectives:
1. Modular Flexibility: Design a modular set that can be reconfigured to support a variety of opera layouts each year, adding versatility and visual interest with levels and angles for dynamic staging.
2. Acoustic Consideration: Ensure that the design enhances the hall’s natural acoustics for both vocal projection and orchestral balance. The modular elements should support singer audibility over the orchestra without amplification.
3. Safe and Accessible Design: Incorporate connections between the upper and lower levels of the hall, expanding staging possibilities. The set must be safe, with easy assembly, disassembly, and storage options.
4. Orchestral Integration: Plan the set layout to accommodate up to a 25-piece chamber orchestra or a grand piano with up to 10 instrumentalists, considering their spatial and acoustic relationship to the singers.
5. Sustainability and Storage: Design lightweight, durable modules that can fit through a 36-inch wide and 8’ tall door and be stored in the designated area (Music Building I, Room 3). All pieces should be on brake hydraulic rubber casters to protect the hall’s wood floor and allow easy movement.

Technical Analysis and Design Considerations: The project will involve:
• Analyzing the recital hall's acoustic characteristics to inform design elements that support unamplified vocal and orchestral sound.
• Creating CAD models for various configurations of the modular set, including specifications for lightweight materials that meet weight restrictions (approximately 800 lbs per foot on contact points).
• Engineering a connection system for upper and lower level integration that ensures performer safety and ease of use.
• Testing the viability of rubber caster wheels and modular finishes for mobility without damaging the hall floor.
• Considering aesthetic finishes that align with operatic staging requirements while maintaining durability and ease of reconfiguration.
•
Justification: This project would provide an affordable initial investment to develop a reusable, sustainable solution for opera staging, with potential applicability in other recital halls facing similar limitations.

Conclusion: The project will provide a meaningful and achievable challenge for a student team, allowing them to apply design and engineering skills to create a unique, reusable solution for opera staging in a recital hall. It will benefit the Penn State community by enhancing operatic productions and serve as a potential model for similar performance spaces elsewhere.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Penn State, College of Medicine 3d printed custom boots for patients with Charcot foot Lei, Yuguo 1 0 0 0 0 3 0 0 0 0 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Diabetes can result in Charcot foot, characterized by desensitization and foot bone damage. Approximately 25% of these patients undergo amputation. Customized boots are currently created for patients by a clinician using manual, time-intensive methods. This project seeks instead to use CT scans of patients’ feet to create customized boots with 3D modeling and 3D printing. The footwear will have the goal of redistributing pressures acting on the sole of the foot, offloading specific regions and preventing further foot collapse. We have available 3d scans of healthy feet and Charcot feet, a preliminary model of a boot, and sensors to measure pressures on the foot. The project is especially well suited for students interested in biomechanics, biomedical devices, 3D printed materials, and/or 3D modeling.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Penn State, College of Medicine Adjustable acetabular cage for hip replacement Hylbert, Lyndsey 1 0 0 0 0 3 0 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The main objective is to develop a new acetabular cage device for hip replacement in the presence of bone defects. The device should enable attachment of an acetabular component with adjustability in position and/or orientation. This project will require device mechanical design and structural analysis (likely including finite element analysis), resulting in a prototype. Students will also need to consider biocompatible materials, surgical constraints, and hip biomechanics, with basic guidance provided by the mentors at Hershey Medical Center.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Penn State, College of Medicine Adjustable angle screwdriver for orthopaedic surgery Hylbert, Lyndsey 2 0 0 0 0 3 0 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Many types of orthopaedic surgery, including joint replacement, fracture repair, and soft tissue reconstructions, involve fixation of screws to bone. In some scenarios, there is limited window of access of the screw driving instrument to the screw head. For example in hip replacement, attachment of the acetabular cup using optimally directed screws is challenging with traditional drivers in some patients due to the cup shape and surrounding soft tissues. The goal of this project is development of a screwdriver device that enables angulation between the axis of torque application and axis of screw rotation. Ideally, the angle could be adjustable for different patients and applications. After understanding the clinical needs, students will design a new surgical device, conduct mechanical analysis, prototype components, and test them.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Penn State, College of Medicine Surgical assistive device for mechanical thrombectomy in stroke patients Medina, Scott 1 0 0 0 0 3 0 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Mechanical thrombectomy is a minimally invasive surgical procedure for removing blood clots in vessels in the brain. The procedure is performed shortly after a patient suffers an ischemic stroke. Using real-time x-ray guidance, small catheter tubes are navigated through the body to targeted vessels in the brain, and miniature devices are then deployed through the tube to grab the clot. The procedures are very delicate operations, and multiple challenges have been identified by a clinical mentor at Penn State Hershey Medical Center. For example, re-insertion of a guidewire into the catheter tube can be quite time consuming and tedious. A successful device used in the operating room would enable patients to be treated for their stroke faster, improving quality of life after stroke. After gaining an understanding of the clinical needs, students will engineer and design these miniature surgical devices, prototype them, and get feedback from clinical expert(s).
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Pennsylvania State University Design and Prototyping of Particle Release Mechanisms for Concentrated Solar Power Towers Toraman, Hilal 0 0 0 0 0 0 0 1 0 0 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This capstone project aims to design and prototype innovative particle release mechanisms for Concentrated Solar Power (CSP) towers, with the primary goal of achieving uniform single-particle profile flow across significant tower heights to optimize heat transfer efficiency and system performance.
The technical challenge stems from current CSP systems' difficulties in maintaining consistent particle distribution during gravitational flow, which directly impacts heat absorption efficiency. The project seeks to develop a mechanism that ensures controlled particle release rate, uniform spatial distribution, minimal particle agglomeration, and stable flow patterns at various heights, all while maintaining resistance to thermal and mechanical stress.
The project will progress through three main phases. The research phase involves analyzing existing particle flow mechanisms, studying analogous systems in pharmaceutical and chemical industries, and reviewing current CSP tower configurations. The design phase encompasses conceptual development, CAD modeling and simulation, material selection considering thermal and mechanical properties, and integration planning with existing CSP tower systems. The final prototyping phase includes fabrication of a scale model, implementation of control systems, testing under various operating conditions, and performance measurement.
The team will deliver detailed design documentation, a working prototype, comprehensive test results and performance analysis, a technical report with recommendations, and cost analysis with scaling considerations. Required resources include CAD software, 3D printing and fabrication facilities, testing equipment for particle flow analysis, materials for prototype construction, and simulation software for flow modeling.
The six-month timeline allocates two months each for research and conceptual design, detailed design and simulation, and prototype fabrication and testing. Success criteria include achieving uniform particle distribution across specified height, maintaining consistent flow rate, demonstrating reliability under extended operation, meeting safety and maintenance requirements, and staying within budget constraints.
The project presents opportunities for innovation in flow control mechanisms, sensor integration, material applications, system automation, and thermal management strategies. The ideal team consists of 4-5 engineering students with diverse backgrounds in mechanical engineering, control systems, materials science, and thermal engineering. This multidisciplinary approach ensures comprehensive coverage of all technical aspects while fostering creative problem-solving in particle flow management for CSP applications.
This project will provide students with hands-on experience in developing cutting-edge renewable energy technology while addressing real-world engineering challenges. The successful completion of this project will contribute to the advancement of CSP technology and potentially lead to improved efficiency in solar power generation systems.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Pittsburgh Foundry and Machine Company New Core Room Zajac, Brian 0 0 0 0 0 3 0 0 0 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The team would design and engineer a core room that would manufacture sand cores for use in our molding and casting production process. Currently, the core room shares space with our floor molding line and we would like to separate them into two spaces, providing more room for core making and a more efficient workflow. This new room would need to connect to the next stage of the manufacturing process; we would like the team to design this connection. Some considerations will be how this core-making interacts with and connects to other steps; we'd like to have it designed so that it may also be ready to connect with manufacturing methods that we may add in the future. In addition to overall productivity and efficiency, we'd like the team to consider sustainable materials and practices wherever possible.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Product Realization Specialties, LLC Natural Gas Sensor Alarm and Shutoff Cubanski, Dave 0 0 2 0 0 0 1 0 0 3 3 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Description: It seems that every few weeks there is a home or business explosion caused by buildup of natural gas or propane in the home or building. Sometimes people are badly burned or killed by the explosion. What is needed is a gas sensor unit (that exists) and a solenoid-controlled master gas shutoff valve (that exists) linked by software and Bluetooth or Wi-Fi to shut off the gas main to the building prior to dangerous gas buildup. The existing sensors are much more sensitive than the human nose. Many lives could have been saved in Reading by preventing the gas explosion at the R.M. Palmer Company candy factory some years ago. In Allentown 5 people were killed in an explosion in 2011. This could have been prevented as well. The students could pitch this concept to the natural gas companies such as UGI. Perhaps they would be willing to help sponsor the project, since it would avoid major lawsuits.
It is expected that the new alarm/shutoff system would use a cost reduced version of the existing natural gas or propane sensors and incorporate a communication PCB plus software to close the incoming main to the building if the gas concentration reaches a threshold level. The system could potentially contact 911 or the gas company so that an emergency technician could be dispatched to the site to investigate. The system would also initiate an audible alarm similar to a smoke detector to evacuate the building.

The capstone project team will need to:

Research and identify existing natural gas and propane sensing systems and evaluate the cost/performance tradeoffs for these systems.

Look for application specific cost reductions for gas sensing systems.

Research and identify existing solenoid-controlled gas main shutoff valves and evaluate the cost/performance tradeoffs.

Develop a Bluetooth or WiFi communication module with an intelligent interface to the gas sensor for operating the solenoid-controlled shutoff valve.

Develop software/firmware to tie together the sensor and gas shutoff valve, create an audible alarm and initiate a contact to 911 or the gas company.

Project deliverables:

A fully functional demonstration unit complete with sensor, shutoff valve, communication system and working software/firmware.

Provisional patent application protecting the hardware and software.

Final report with financial analysis and cost estimate for a production version of the final product.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Engineering Leadership Development Electronic Agile Workshop Game Zajac, Brian 0 0 3 3 0 0 3 0 3 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Traditionally, Agile principles were created and have been used for software development teams; however, as teams become more multidisciplinary and organizations search for methods to streamline development and collaboration, there is a growing desire to expand Agile principles across many facets of multidisciplinary project management. See more here: https://agilemanifesto.org/ The Engineering Leadership Development program provides students with opportunities to learn how to lead multidisciplinary teams through the engineering design and development process. This happens in various curricular and extracurricular activities, including workshops specific to Agile Project Management. Currently, students learn about Agile Project Management by participating in a fun, interactive game utilizing play "pit balls" (the kind you used to jump into when you were a kid!). Attached are the specific instructions for the game. The primary purpose is to illustrate the mechanics of Agile Scrum through Planning, Execution, and Retrospective. Each period is timed with team effectivity and efficiency measured based on the successful processing of balls. In order to keep track of time, a separate, manual timer is displayed on a projector, and metrics are tracked on a chalk / whiteboard. The metrics include: Plan, Actual, Defects, Total, and Delta. The three primary goals of this project would be to: 1) Create an electronic "system" for tracking and displaying the team's progress through multiple sprint periods, 2) Create a portable packaging solution that can be easily taken anywhere across campus by a single person, and 3) Create an environment that adds an element of Excitement, Stress, and FUN!
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Engineering Leadership Development One Penn State: Streamlining Multi-Campus Course Offerings Zajac, Brian 0 0 0 2 0 0 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The Engineering Leadership Development (ELD) program is housed with the College of Engineering's School of Engineering Design and Innovation, and they provide technical and professional educational opportunities specific to students in STEM majors. The majority of students that participate with ELD are pursuing a minor in Engineering Leadership Development. In recent years, the ELD program has expanded their course offerings to provide an opportunity for students at ANY Penn State campus to pursue the ELD minor. Cross-campus course "sharing" is facilitated through an online system called the Digital Learning Cooperative (DLC). The current process for listing and enrolling in courses on the DLC suffers from multiple problems which limits student enrollment. This includes, 1) manual and cumbersome listings, 2) limited student and administrator awareness of listings, 3) communications break downs, and 4) unclear timelines. The ultimate goals of this project are to make the process more efficient and to increase overall enrollments. A successful output from this project would be 1) a clear articulation of the current process required for promoting classes across the commonwealth, 2) a timeline of events, 3) suggestions for streamlining administrative duties such that the process is easily repeatable with minimal prior knowledge or experience, 4) Automated Tooling and/or Standard Operating Procedure generation.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Huck Institutes of the Life Sciences and College of Arts and Architecture Ex-Utero: Designing a Living System for In-Vitro Tissue Engineering Lei, Yuguo 1 0 0 0 0 0 0 0 0 0 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Overview:
The placenta is an understudied and invaluable biological resource that shows great promise in regenerative medicine and tissue engineering research. As a largely discarded tissue rich in extracellular matrix (ECM), the placenta is an excellent candidate for biological scaffolds in reconstructive medicine. We aim to decellularize the entire placenta and seed the extracellular matrices with foreign cell lines. In this initial phase of the project, the goal is to produce a prototype to decellularize, and ideally, reseed, a small section of the umbilical cord.

The decellularization process removes all the cellular components, resulting in a biomaterial scaffold for tissue regeneration. This groundbreaking research aims to eliminate the risk of immune rejection and shows great promise for the future of organ transplantation. The placenta, along with the umbilical cord, are central to advances in regenerative medicine with widespread applications in wound healing, ophthalmology, skin grafts, breast reconstruction, and more.

"Ex-Utero" is an artistic and scientific inquiry into the future of human reproduction and probes the biological and sociopolitical possibilities of ectogenesis, the development of the embryo outside the uterus. In the foreseeable future, artificial wombs may support life ex-vivo, and the placenta, a critical gestational organ, will become obsolete.

Deliverables:
• Design of a portable system to:
- decellularize a section of umbilical cord via the vascular network of the umbilical cord through perfusion and diffusion
- reseed the ECM with living cells
- sustain and support the viability of the reseeded cells

• Initial Prototype
• Functionality testing
• Final Prototype

• Instruction manual that includes:
- a materials and parts list and suppliers
- a schematic diagram of the design and construction
- assembly instructions
- disassembly instructions
- troubleshooting guide

• Summary report of final design
• Final report and presentation
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Industrial and Manufacturing Engineering System and application for tracking car parking locations in a multi-story indoor garage Zajac, Brian 0 0 3 2 0 3 3 0 3 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

In this project, we will develop a hardware system and mobile application for tracking car parking locations in a multi-story, indoor parking garage. During peak hours, drivers have to park in one of the few parking spots that are available, and later on have difficulty in remembering where they parked their car. This application can mitigate the situation by guiding the drivers to their car's parking spot. Similar solutions already exist for outdoor parking using basic GPS technology, but these systems fail to perform underground or in multi-story structures due to the obstructed sky and challenging radio frequency (RF) environment.

Although this solution can be used in large parking garages such as at amusement parks or in downtown offices, we plan to test it at the West Parking Deck at Penn State University. Students working on this project will complete 3 primary tasks throughout this project:

1) Investigate the market and evaluate novel methods of tracking a car's location using Bluetooth or other low cost, widely accessible technologies
2) Develop a hardware system and simple mobile app to demonstrate their novel solution in a real-world environment
3) Submit an Invention Disclosure and pursue a patent with assistance from PSU's Office of Technology Transfer (OTT)

The OTT will assess the invention and determine possible commercial or protection strategies, so a patent may not directly result from this project. However, the goal is to familiarize the team with the patent application process and students will own any intellectual property (IP) that they produce.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Mechanical Engineering Extendable Electric Wall Outlet Wang, Chao-Yang 0 0 0 0 0 3 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project is ideal for students interested in product development, electro-mechanical design, high and low voltage wiring, AC/DC conversion and with an interest or experience in home construction or remodeling. This project will focus on developing an electric wall outlet with a built-in retractable extension mechanism. Deliverables include building a working prototype of the proposed product utilizing rapid prototyping components and salvaged parts from existing products for sale. Additional deliverables could include a potential marketing campaign with product name and builder value proposition, and a business case with estimated Cost of Good Sold (COGS) and tooling costs.  Design would be expected to consider manufacturability, durability, serviceability, installability and meet current regulatory requirements such as UL and IRC building code.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Quaker Houghton Metalworking Fluid Performance in Discontinuous Cutting of an Aluminum Alloy Zajac, Brian 0 0 0 0 0 0 0 0 0 1 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Metalworking Fluid Performance in Discontinuous Cutting of an Aluminum Alloy

Background
The machining performed in the manufacture of aluminum wheels includes hole making operations, rough and finish turning as well as final polishing steps done to give the wheel surface a bright and shiny appearance. The finish turning operation is an important operation in that the roughness and appearance of the turned surface largely influences the surface quality and appearance of the final wheel. This proposed project aims to study the effects of machining conditions as well as metalworking fluid performance in the finish turning of Aluminum alloys, which are widely used in wheel production. Using a turning operation on the outer diameter of aluminum cylinders, with notches on the OD to help simulate the discontinuous cutting that takes place during aluminum wheel machining, the effects of metalworking fluid performance will be studied regarding machined surface roughness and appearance, insert wear, burr formation, and the level of aluminum welded or transferred to the cutting insert.
Deliverables:
1. Using a horizontal machining center, complete single point finishing operation on Al cylinders with notches while using cutting conditions and tooling consistent with those utilized in industrial Al wheel machining operations.
2. Conduct testing of three different metalworking fluids in the OD turning of the Al alloy fluid performance via measurement of machined surface roughness, appearance and texture, as well as by measurement of the tool wear, metal (Al) build-up formed on the cutting insert and a strong emphasis on burr formation during the machining operation.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
REID Lab Decision Support System to Enhance Situational Awareness in High-Risk, Low-Time Scenarios - Team 1 Lewis, Alfred (Scott) 0 0 2 3 0 0 0 0 0 3 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Many professionals such as fire fighters, emergency medical service workers, and police officers often have to respond to situations that are high risk and with very little time to respond. Such work environments can challenge workers’ situational awareness, and in some cases lead to fatal errors.  The recent media has highlighted several instances in which incorrect assessment of situations lead to fatal outcomes . In this project, students will contribute to answering the following broad research question: “How can we support the situational awareness of workers in high risk, low time scenarios?” This project develop a proof of concept showing how this can be implemented in practice.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
REID Lab Decision Support System to Enhance Situational Awareness in High-Risk, Low-Time Scenarios - Team 2 Verbanec, Alan 0 0 3 1 0 0 0 0 0 3 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Many professionals such as fire fighters, emergency medical service workers, and police officers often have to respond to situations that are high risk and with very little time to respond. Such work environments can challenge workers’ situational awareness, and in some cases lead to fatal errors.  The recent media has highlighted several instances in which incorrect assessment of situations lead to fatal outcomes . In this project, students will contribute to answering the following broad research question: “How can we support the situational awareness of workers in high risk, low time scenarios?” This project develop a proof of concept showing how this can be implemented in practice.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
REID Lab Tailored Care: Adaptable Digital Twin-based Devices for Enhancing Physical Wellness in Elderly Individuals Lewis, Alfred (Scott) 2 0 3 3 0 0 3 0 0 3 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Problem Identification

By 2030, 1 in 4 adults in the U.S. will be over the age of 65, presenting a significant challenge for healthcare systems to address the evolving needs of the aging population. As people age, physical abilities such as mobility, balance, and strength naturally decline, which can affect their ability to perform daily activities like walking, sitting, or maintaining proper posture. This decline not only impacts their independence but also their overall health and quality of life. The challenge lies in developing data-driven, adaptive and innovative devices that can help seniors maintain their physical wellness, support their daily activities, and promote independence. These devices also need to provide caregivers and healthcare professionals with real-time data, enabling them to track physical progress, identify early signs of decline, and make data-driven decisions for improved care outcomes.

Project Description:

This aim this project is for students to design and develop an adaptive device tailored to meet the evolving physical needs of elderly individuals, particularly those requiring enhanced support for mobility and daily activities. The device will integrate a ‘digital twin’—a virtual model that continuously reflects the real-time physical state of the user. Through the use of real-time monitoring, the device will track key metrics such as mobility, posture, and balance, allowing it to detect changes in the user’s physical condition. The system will then leverage this data to automatically adjust and provide personalized support, ensuring that the device adapts to the individual’s specific needs over time. The primary objective is to create a solution that not only aids physical wellness for changing physical requirements of the elderly but also enables healthcare providers and caregivers to monitor the user’s progress, identify potential risks, and make data-driven decisions to enhance care outcomes.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
REID Lab Tracking the Body’s Journey: Integrated Device Systems for Monitoring and Measuring Physical Wellness in the Elderly Lewis, Alfred (Scott) 2 0 3 3 0 3 3 0 0 3 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Problem Identification

The United States is experiencing a significant demographic shift, with the elderly population projected to reach nearly 20% of the national population by 2030. This growing demographic presents unique opportunities for the healthcare industry and practitioners to develop interventions that support the needs of this population. With age, elderly individuals naturally experience a change in their physical abilities. These age-related changes impact activities where strength, balance, mobility, positioning, and posture are required and any decline to these factors can impact their independence, quality of life, and overall health. As a result, there is a critical need for innovative systems that can support elderly individuals in maintaining their wellness while providing their healthcare practitioners and caregivers with timely, data-driven measures to help enabling caregivers and healthcare practitioners to be provided with timely, data-driven care.



Project Description

The objective of this capstone project is to design a user-centric integrated system for real-time monitoring of the physical well-being of elderly individuals. The system will utilize a digital twin-based approach, where a sensor-based device captures live metrics of an individual’s physical movements, posture, and balance. These metrics may be continuously transmitted to an online platform or digital environment, creating a real-time representation of the user’s physical state. Such a system can improve the detection of risks, such as falls, and provide actionable insights to healthcare providers and assistive technology designers. The digital twin will enhance personalized care experience and promote independence for elderly individuals. The project emphasizes the development of technology that is reliable, user-friendly, and suitable for the unique needs of elderly users. It also addresses the importance of seamless data integration into digital platforms, prioritizing accuracy, security, and accessibility to ensure the system’s effectiveness in real-world applications.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
RERC on AAC ChatBot to support the practice of active listening skills Verbanec, Alan 0 0 2 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project will leverage currently available LLMs (Large Language Models) to create a chatbot for pre-service teachers to practice communication with parents using the LAFF “active listening” strategy. Active listening is the process of paying close attention to what someone is saying, and demonstrating understanding by reflecting back what is heard, asking clarifying questions, and summarizing understanding of the speaker’s message. The LAFF active listening strategy (McNaughton et al., 2008) is a research supported approach to a more positive communication experience for parents and education professionals.

This chatbot will be created as an H5P plugin for use within Moodle LMS modules. The LLM will require background information but the team will help determine what information is required for “realistic” interactions via a text interface. Background information will be entered into the LLM to provide the foundation for the interaction , and will include a biography of the parent, the child, and the parent’s concern about the child. The chatbot should leverage the LLM to identify which steps of the LAFF strategy (e.g., Listen and communicate empathy, Ask questions, etc) are used by the “professional” during the interaction, and provide a report on which steps have been included/not included.

It would be great if the chatbot can also leverage the LLM to provide opportunities for the “professional” to practice the use of the strategy with parents in different “moods” ( e.g., reluctant to answer questions, angry and confrontational, etc). The final plugin for the moodle LMS should include a professional looking UI, a method to switch between multiple stored situations (i.e., different “parents” and child situations) and return necessary grade information on the use of the LAFF strategy to the Moodle LMS.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Restek Corporation A Capillary Array Container Wang, Chao-Yang 0 0 0 0 0 2 0 0 0 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Figure 1 illustrates the design project. Our current assembly is an array of 12 fused silica capillaries, housed in a plastic tube container. The capillaries are sealed into the container with epoxy, and the terminal ends of the capillaries protrude from the container.

We are looking for:

(1) a design that cleanly cuts twelve fused silica capillaries in the cutting mechanism region as illustrated in the figure. This function is driven by a simple hand operation by the user, e.g., by twisting, pushing, squeezing, etc. the cutting mechanism.

(2) a cap design that encloses the capillary array ends in the cap device region.
During storage of the assembly, the terminal capillary ends are protected by a cap that is removably attached to the plastic tube container.

The cutting mechanism may be integrated into either the cap device or the plastic tube container. The capillaries are to be cut as part of the function of removing the cap. We want both the removal of the cap and the cutting of the capillaries to be achieved in a single action.

Preferably, the sheared pieces of the capillary ends are retained by the cap device after removal.

(3) We are also interested in a manufacturing means to make the finished 12-Capillary Assembly. Initial forecasted volumes are 50,000 units/year, scalable to 500,000 units/year.

Target price for the entire assembly is <$12.00.

To facilitate the cap / cutting mechanism designs, modification of the existing plastic tube and (to a lesser extent) the geometry of the 12 capillary array is permitted.
Currently, the radial geometry of the capillary array potted in the epoxy is circular (Figure 2). Only at the epoxy region are the capillaries anchored. They are individually separate in the cap device region. This capillary arrangement is also negotiable in the final design.

Restek will provide additional details regarding the capillary and enclosure materials.
Restek will provide materials and engineering resources for the duration of this project
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Robert Gordon Ind. dba Gordon Sinclair Production Layout Zajac, Brian 0 0 0 0 0 2 0 0 0 1 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Review our current plant and production layout and advise on changes to minimize handling and improve production throughput.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
SBT Ultrasonic Technology Co., Ltd. High Precision Advanced Packaging Solder Head Module Design and Development - SJTU Global Project Neal, Gary 0 0 0 0 0 0 0 0 0 2 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Advanced packaging technology aligns with the trend of high-end chips evolving towards smaller sizes, higher performance, and lower power consumption. As Moore's Law gradually slows down, driven by new technologies such as Chiplet and HBM, advanced packaging becomes increasingly important. In the post-Moore's Law era, the focus of semiconductor industry development shifts from further improving wafer manufacturing technology nodes to packaging technology innovation. Advanced packaging has become a crucial path to counteract the physical limitations posed by the slowdown of Moore's Law. The growing demand for advanced packaging has made advanced packaging equipment highly valued and prioritized, with capital expenditure increasing year by year and a huge market capacity for equipment. One of the most critical core components of advanced packaging is the solder head module. It requires Z+ rotation ? and horizontal adjustment, equipped with precise force control and temperature control. Not only does it need to utilize advanced motion control, vibration design and control, precision drive mechanisms, and high-performance materials, but it also faces constraints in space and quality, making its realization a significant challenge.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
School of Engineering Design and Innovation Stretch Assignment Application for Professional Development Mittan, Paul 0 0 2 1 0 0 0 0 3 3 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The School of Engineering Design and Innovation (SEDI) is centrally housed within the College of Engineering and provides students with the critical skills necessary to succeed as engineers through cornerstone engineering and a variety of professional development programs. SEDI Faculty provide a diverse set of technical and professional skills that align with nearly all departments within the College of Engineering. Additionally, many of the SEDI programs span the entire Commonwealth, positioning SEDI to facilitate collaboration between students and faculty at any Penn State campus. However, to date, there is no streamlined method for communicating professional and/or technical development opportunities across all these stakeholders.

The primary goal of this project is to create a web-based “Stretch Assignment” database for promoting professional and technical development opportunities for full-time employees across the College of Engineering. In this case, “Stretch Assignment” is defined as a temporary opportunity with a finite period of performance that would provide new knowledge or a new skillset to assist the employee in their professional and technical development. Stretch Assignments would typically be conducted in addition to the employee’s regular responsibilities and would not require a job change. Initially, the target audience for this application would be faculty, but staff may also be included. Stretch Assignments may or may not be paid opportunities and would be categorized as aligning with Administrative, Teaching, Research, or Service.

The student design team is expected to develop an application that will be ready for deployment by Summer 2025. The application should be hosted on a PSU website and allow for both front-end user engagement as well as back-end administrative management. Additionally, an administrative dashboard should provide a real-time look into the platform’s utilization.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Seco Tools Automated Tool Imaging Station Zajac, Brian 0 0 3 0 0 2 0 0 0 1 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

As part of the testing process of cutting tools, a number of images have to be taken regularly. Those images are aiming to capture the wear behavior of the tool. The purpose of the project is to design and prototype a system able to take pictures at defined positions on the tool.

The overall objectives are as follows:
- The system, after initial teaching, should be able to replicate imaging positions accurately.
- The system will need to work with the tool mounted in its tool holder.
- Top views and side views (of all around the cylindrical tool) should be attainable for the typical tool dimensions used in our facility.
- The system should be easily configurable for different tool dimensions and imaging locations.
- The system should have adjustable lighting to guarantee high quality imaging.

As a deliverable to the project, a proof of concept should be designed, and an estimated cost of the solution should be provided.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Shanghai JingXie 3D technology Co., LTD Thermodynamic Study on A Cooling Window Based on Ferroelectric polymer films - SJTU Global project Neal, Gary 0 0 0 0 0 0 0 0 0 0 2 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The electrocaloric effect, recognized for its zero greenhouse emissions, high energy efficiency, and superior power density, has been identified by the United States Department of Energy as a key technology for the next generation of zero-carbon refrigeration technologies. The objective of this project is to design and manufacture a novel prototype of a solid-state, high-efficiency, zero carbon emission electrocaloric refrigeration system for window applications. This system will be based on the physical principles of the electrocaloric effect, involving the design and fabrication of a polymer-based electrocaloric refrigeration composite material with high electrical-to-thermal energy conversion efficiency. Additionally, the project aims to investigate the relationship between structure and performance across sub-nanoscale, nanoscale, and microscale dimensions within the composite material, optimize the fabrication process for the polymer electrocaloric refrigeration films, and enhance the efficiency of the electrocaloric refrigeration cycle. The ultimate goal is to fabricate a highly efficient film electrocaloric refrigeration component and design a flexible film window air conditioning prototype that operates without external mechanical drives and possesses an exceptionally high power-to-weight ratio, thereby advancing the practical application of electrocaloric refrigeration technology.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Shell 1 Shell Ecomarathon - Team 1 Neal, Gary 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Shell Eco-marathon (https://www.shellecomarathon.com/) is a global student engineering competition focused on automotive energy optimization. The goal is to design and build a crazy fuel-efficient vehicle that meets all the competition rules and then compete against nearly 100 other North and South American schools to see who did the best. The competition will be held at the Indianapolis Motor Speedway, and winners in our category routinely achieve > 500 mpg. Penn State’s Ecomarathon club (https://sites.psu.edu/pennstateecomarathon/) has performed well for over 20 years, and we’re now leveling up our game. In collaboration with the PSU student club, these capstone teams will integrate recent competition lessons learned into the ground up design of a brand-new vehicle. This project will design, build, and test that vehicle, first at our Penn State Test Track and ultimately at the Shell Ecomarathon competition. Ya, we actually drive our car on the Indianapolis Motor Speedway! Some cool things you may do to create our winning car include mechanical design using CAD modeling, finite element analysis, and computational fluid dynamic aero analysis; automotive electrical system design and construction; steel tubing and aluminum sheet metal cutting, bending, and welding; carbon fiber fabrication; small displacement engine powertrain implementation and optimization; and many others.

If you want a hands-on experience where you will design and build a real car; have a competitive spirit and want to see Penn State win; are into sustainable automotive technologies; or want the chance to compete on the Indianapolis Motor Speedway, then this is the project for you!
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Shell 2 Shell Ecomarathon - Team 2 Neal, Gary 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Shell Eco-marathon (https://www.shellecomarathon.com/) is a global student engineering competition focused on automotive energy optimization. The goal is to design and build a crazy fuel-efficient vehicle that meets all the competition rules and then compete against nearly 100 other North and South American schools to see who did the best. The competition will be held at the Indianapolis Motor Speedway, and winners in our category routinely achieve > 500 mpg. Penn State’s Ecomarathon club (https://sites.psu.edu/pennstateecomarathon/) has performed well for over 20 years, and we’re now leveling up our game. In collaboration with the PSU student club, these capstone teams will integrate recent competition lessons learned into the ground up design of a brand-new vehicle. This project will design, build, and test that vehicle, first at our Penn State Test Track and ultimately at the Shell Ecomarathon competition. Ya, we actually drive our car on the Indianapolis Motor Speedway! Some cool things you may do to create our winning car include mechanical design using CAD modeling, finite element analysis, and computational fluid dynamic aero analysis; automotive electrical system design and construction; steel tubing and aluminum sheet metal cutting, bending, and welding; carbon fiber fabrication; small displacement engine powertrain implementation and optimization; and many others.

If you want a hands-on experience where you will design and build a real car; have a competitive spirit and want to see Penn State win; are into sustainable automotive technologies; or want the chance to compete on the Indianapolis Motor Speedway, then this is the project for you!
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Shell 3 Shell Ecomarathon - Team 3 Neal, Gary 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Shell Eco-marathon (https://www.shellecomarathon.com/) is a global student engineering competition focused on automotive energy optimization. The goal is to design and build a crazy fuel-efficient vehicle that meets all the competition rules and then compete against nearly 100 other North and South American schools to see who did the best. The competition will be held at the Indianapolis Motor Speedway, and winners in our category routinely achieve > 500 mpg. Penn State’s Ecomarathon club (https://sites.psu.edu/pennstateecomarathon/) has performed well for over 20 years, and we’re now leveling up our game. In collaboration with the PSU student club, these capstone teams will integrate recent competition lessons learned into the ground up design of a brand-new vehicle. This project will design, build, and test that vehicle, first at our Penn State Test Track and ultimately at the Shell Ecomarathon competition. Ya, we actually drive our car on the Indianapolis Motor Speedway! Some cool things you may do to create our winning car include mechanical design using CAD modeling, finite element analysis, and computational fluid dynamic aero analysis; automotive electrical system design and construction; steel tubing and aluminum sheet metal cutting, bending, and welding; carbon fiber fabrication; small displacement engine powertrain implementation and optimization; and many others.

If you want a hands-on experience where you will design and build a real car; have a competitive spirit and want to see Penn State win; are into sustainable automotive technologies; or want the chance to compete on the Indianapolis Motor Speedway, then this is the project for you!
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Shell 4 Shell Ecomarathon - Team 4 Neal, Gary 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Shell Eco-marathon (https://www.shellecomarathon.com/) is a global student engineering competition focused on automotive energy optimization. The goal is to design and build a crazy fuel-efficient vehicle that meets all the competition rules and then compete against nearly 100 other North and South American schools to see who did the best. The competition will be held at the Indianapolis Motor Speedway, and winners in our category routinely achieve > 500 mpg. Penn State’s Ecomarathon club (https://sites.psu.edu/pennstateecomarathon/) has performed well for over 20 years, and we’re now leveling up our game. In collaboration with the PSU student club, these capstone teams will integrate recent competition lessons learned into the ground up design of a brand-new vehicle. This project will design, build, and test that vehicle, first at our Penn State Test Track and ultimately at the Shell Ecomarathon competition. Ya, we actually drive our car on the Indianapolis Motor Speedway! Some cool things you may do to create our winning car include mechanical design using CAD modeling, finite element analysis, and computational fluid dynamic aero analysis; automotive electrical system design and construction; steel tubing and aluminum sheet metal cutting, bending, and welding; carbon fiber fabrication; small displacement engine powertrain implementation and optimization; and many others.

If you want a hands-on experience where you will design and build a real car; have a competitive spirit and want to see Penn State win; are into sustainable automotive technologies; or want the chance to compete on the Indianapolis Motor Speedway, then this is the project for you!
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Shell 5 Shell Ecomarathon - Team 5 Neal, Gary 0 0 0 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Shell Eco-marathon (https://www.shellecomarathon.com/) is a global student engineering competition focused on automotive energy optimization. The goal is to design and build a crazy fuel-efficient vehicle that meets all the competition rules and then compete against nearly 100 other North and South American schools to see who did the best. The competition will be held at the Indianapolis Motor Speedway, and winners in our category routinely achieve > 500 mpg. Penn State’s Ecomarathon club (https://sites.psu.edu/pennstateecomarathon/) has performed well for over 20 years, and we’re now leveling up our game. In collaboration with the PSU student club, these capstone teams will integrate recent competition lessons learned into the ground up design of a brand-new vehicle. This project will design, build, and test that vehicle, first at our Penn State Test Track and ultimately at the Shell Ecomarathon competition. Ya, we actually drive our car on the Indianapolis Motor Speedway! Some cool things you may do to create our winning car include mechanical design using CAD modeling, finite element analysis, and computational fluid dynamic aero analysis; automotive electrical system design and construction; steel tubing and aluminum sheet metal cutting, bending, and welding; carbon fiber fabrication; small displacement engine powertrain implementation and optimization; and many others.

If you want a hands-on experience where you will design and build a real car; have a competitive spirit and want to see Penn State win; are into sustainable automotive technologies; or want the chance to compete on the Indianapolis Motor Speedway, then this is the project for you!
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Structural Integrity Associates Enhanced Data Acquisition System for Superior Field Performance Banyay, Greg 0 0 3 0 0 1 3 0 0 0 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The data acquisition system (DAS) developed at Structural Integrity Associates (SIA), known as Fire Engine system is a robust and portable data acquisition solution developed for measuring accelerometers and other instrumentation in challenging field environments. Designed to endure extreme conditions, including severe vibration and background noise, high impact, harsh weather, and temperature extremes, the system is utilized in industrial settings requiring reliability and compactness. The current CAPSTONE project focuses on upgrading the Fire Engine to improve functionality, durability, and adaptability for diverse applications.

Key upgrades include:

1. Battery Backup Integration: Ensuring uninterrupted operation during temporary power outages, the project involves identifying a compact, off-the-shelf solution that can provide at least 10 minutes of backup power. The chosen system must fit within the existing cabinet and withstand field transport conditions.
a. The potential electrical Noise should be anticipated and filtered, and the quality of data should not be decreased.
b. Battery Recharging, should not change temperature inside the DAS

2. Integrated 120V Power Output: Adding a dedicated 120V output allows the Fire Engine to power auxiliary devices, such as laptops, eliminating the need for external power strips and streamlining field setups.

3. Connection Panels Options

i. Strain Gauge Recording Panel: Designing a modular panel to facilitate strain gauge data acquisition supports up to 16 channels with configurable circuit options (¼, ½, and full bridge configurations). This panel will include features such as completion resistors and grounding dip switches, optimizing it for flexibility in various field applications.

ii. Improved BNC Panel Connectivity: Addressing noise issues caused by microdot connectors, the project seeks to enhance the reliability of connections between the NI-9231 module and the BNC panel. Proposed solutions include circuit board-mounted connectors and a robust external interface to reduce data inconsistencies.

iii. Laser Distance Sensor Panel: Developing a modular and swappable panel for integrating laser distance sensors includes provisions for power supply and streamlined connections to the DAS system. This addition enhances the system’s versatility for distance measurement applications.

This comprehensive upgrade project emphasizes innovative engineering design, seamless integration of components, and rigorous testing to ensure field readiness. The enhanced Fire Engine will serve as a versatile and reliable tool for diverse data acquisition needs.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Swappify LLC Swappify, The Clothing Swapping App Verbanec, Alan 0 0 2 1 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This semester, coders will focus on improving Swappify by enhancing security, usability, and overall performance.
Key tasks include:
- Security
- Usability
- Gamification
- Bug Fixing & Optimization
- Code Quality

Coders will improve both the functionality and user experience of Swappify, while utilizing modern app building languages and software like TypeScript, React, Supabase, and Tailwind CSS.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Aluminum Association, Inc. Aluminum Tolerance Calculator Phase II Zajac, Brian 0 0 3 1 0 3 0 0 3 3 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Introduction and Background:
The Aluminum Association represents aluminum production and jobs in the United States, ranging from primary production to value added products to recycling, as well as suppliers to the industry. As the industry’s leading voice in Washington, D.C., the Association provides global standards, business intelligence, trade policy and expert knowledge to member companies and policy makers nationwide while being committed to advancing aluminum as the prime sustainable metal of choice around the world. The Association’s Standards department develops and maintains technical standards and publications that aid the producers and customers of primary aluminum and aluminum alloy semi-fabrications (semi-fabrication: processes that transform aluminum into a semi-finished intermediate products).
One of our standards widely in use is Aluminum Standards & Data (AS&D), a standard that contains multiple chapters’ worth of tolerancing data for semi-fabricated aluminum products and is available in a U.S. customary units version and a metric units version. These products are used in numerous applications across a wide range of industries including aerospace, automotive, and structural engineering. Standardization often demands the use of intricate criteria and methods to ensure repeatability and reproducibility of prescribed instructions, and to reduce ambiguity in interpretation. Standardization is a means for providing clear technical information and we are exploring how novel methods could be used to make them more user-friendly to the target audience. We have used illustrative examples and explanatory videos to aid the users of our standards to commendable effect. We are now looking to combine modern software tools and to engage sharp engineering minds to develop efficient, interactive ways to make technical standards intuitive and easy to master

Project Overview:
The goal of this project is to continue the development of a digital resource that can help users accurately determine what tolerances apply to their products they make or purchase. As a starting point for this project, we have selected tolerances that apply to extruded wire, rod, bar and profiles fabricated using aluminum alloy-tempers (which are illustrated by a series of tables in AS&D Chapter 11). Tolerances that apply may include dimensions (e.g., thickness), straightness, flatness, angularity, twist, and more. Typically, for a specified thickness, width and/or diameter range, industry established tolerance limits for each of these parameters can be determined from these tables. Adding further complexity are multiple footnotes that define additional criteria that apply to each table and their elements within, making them an integral part of the tolerance calculation process.
In Fall 2024, the Aluminum Calculator Tolerance team at PSU’s Learning Factory developed a prototype for table 11.2 that could accept property and dimension inputs from the user and calculate tolerance that apply for the section that took into account all the complexities of table 11.2 including its footnotes. This was achieved using PostegreSQL and PG Admin. The phase II team (Spring 2025) will inherit this prototype and will be tasked with expanding the resource to more tables of AS&D chapter 11. The Phase II team is encouraged to employ their creativity to refine and enhance the model developed by the prior team and to take it forward in their own direction, provided that it stays on track to achieve the original objective of serving as a high fidelity digital representation of the material in AS&D.
The end result of this project is to create a helpful resource that could be packaged with the publication itself or made available separately on our website. A more advanced idea, or a stretch goal, would be to develop a program that can analyze an imported 2D CAD drawing of an extruded cross-section and subsequently recognize and recommend what tolerances apply for each of the geometric features of the cross-section. The project team is encouraged to come up with their own solutions while capitalizing on the material developed by their predecessors. The best deliverables would be both easily editable to update with revised values to keep up with revisions to the publications and easily expandable to include product forms other than extrusions that are covered therein.

Project Deliverables:
A web-based or standalone resource/program that can be used in conjunction with the tables in AS&D chapter 11 to interpret tolerances that apply to aluminum extrusions with both accuracy and efficiency. The resource/program should be capable of easy editing to accommodate revisions and easy expansion to include other AS&D chapters in the future.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Boeing Company Modeling and Simulation of a Commercial Airplane Airflow and Smoke Suppression System Lewis, Alfred (Scott) 0 0 0 0 0 0 0 0 2 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The primary objective of this project is to develop a computational model and representative prototype of an aircraft fuselage to study and understand the effects of air flow rate, flow patterns, pressure differential, and return air flow rates on the ability to mitigate contaminants from entering the main cabin.

Deliverables:
CDR Presentation Package
CFD Modeling results and predictions
Scaled prototype to demonstrate
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Johns Hopkins University Applied Physics Laboratory Flexible Thermal Protection System Kimel, Allen 0 0 0 0 0 0 0 0 3 0 1 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Concept:
Extreme aerothermal heating threatens structural components during high-speed flight. Thermal protection systems (TPS) serve as resilient external insulation to withstand high temperatures, in excess of 1000°C, in oxidative environments. State-of-the-art materials are rigid ceramic coatings and polymer-ceramic composites that limit versatility in design. We propose to investigate flexible TPS materials that exhibit a high degree of flexibility and elasticity that will facilitate bonding to non-planar surfaces and mitigate thermally induced stresses associated with the dilation of heated materials.

Description:
The team will explore, identify, and characterize polymeric matrices and constituents that are conducive to thermal insulation and oxidation resistant behaviors while maintaining elastic properties. Common and low-cost polymer binders and glass-ceramic fillers will be combined and formulated into test coupons and prototypes materials. Oxidation resistance performance of prototype materials will be evaluated using high heat flux testbed (Oxy-acetylene torch/JHUAPL High Velocity Oxy-Fuel Testbed) to refine and iterate on formulation.


Tasks/Deliverables:
Perform analysis and material selection of matrix and constituent materials
Identify suitable processing method(s) for mixing and applying material to substrates
Produce representative prototype coupons
Characterize properties and performance of material
Analyzing test data for optimization of material composition and microstructure
Final report and presentation

Concepts Learned:
Material Design – formulation and fabrication
Material Processing/Handling – mixing (milling, grinding), coating, etc.
Characterization – leverage test data and material science methods to extract properties and inform design decisions
Testing – develop test fixtures and instrumentation (TC/pyrometry) for monitoring coupon temperatures
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Learning Factory Dog running harness/rescue sling Smith, Tahira Reid 0 0 0 0 0 3 0 0 0 3 2 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Bear is an adventure-loving dog and loves nothing more than trail running. His daily runs take him up and down mountains, through the rough and rocky terrain that make up Pennsylvania’s woods. The purpose of this project is to design a running harness for Bear that can convert into an emergency sling for his owner to carry him out of the woods in the event of an injury or emergency. The harness should function as a comfortable, everyday running harness, but have the ability to convert to a sling in rare scenarios where this might be required. This harness should be lightweight, breathable, durable, and strong enough to hold up to Bear’s daily trail runs. This harness should also be washable and should incorporate blaze orange color for safety and visibility during hunting season. The team can also explore adding the ability to carry outdoor essentials such as water, an emergency blanket, etc… The harness should have a strong connection point to attach a leash and have an adjustable fit. Students will be expected to deliver a final prototype of the harness to their sponsor at the conclusion of the project.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Penn State Learning Factory AI Scheduling System Zajac, Brian 0 0 0 2 0 0 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Scheduling is a large and time consuming portion of the staff at the Learning Factory. We support a lot of classes, students, and outside engagement events. The primary objective of this project is to create a scheduling system that collects data from a defined sources (IE: Microsoft forms) and builds an optimal schedule for these types of engagement events. The secondary objective of the project is utilize AI to optimize scheduling performance, reliability and user accessibility. Stretch objectives can include utilizing base scheduling platform to schedule employee/staff scheduling, apply schedules to various calendars, and send automated notifications to users and other that interface with the system.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Penn State Learning Factory Digital Building Display Verbanec, Alan 0 0 3 1 0 3 3 0 0 2 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project is to design and deploy prototypes of a system that students, faculty or staff that interact with the EDI building and its manufacturing resources can use to explore available technologies in a space. The map would be presented in the form of a virtual map that includes floor plans and equipment available and the equipment's relevant information. For example, we have a woodshop available for end users. We would like to have each piece of equipment selectable on the map so that users could explore its functionality, usage, training requirements, etc. This project could also be used for branding and space promotions (similar to a virtual tour for outside interest).
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Penn State Learning Factory Multifunctional Display Clock for the 4th Floor Learning Factory Makerspace Mahmoodi Takaghaj, Sanaz 0 0 2 3 0 3 1 0 0 3 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The inspiration for this project stems from the "ticker tapes" used in stock market trading centers, designed to maximize visibility and information dissemination. The clock must be viewable from all angles within the makerspace and feature customizable capabilities, enabling it to display not only the time but also Learning Factory announcements, the logo, weather updates, and more. It should integrate seamlessly with the aesthetic and decor of the Learning Factory's 4th floor, using LED matrix panels for the display technology. These panels should be capable of showing both alphanumeric text and simple graphics.
The project requires the development of custom software or the adaptation of existing programmable solutions to manage the display content, ensuring that updates and modifications can be made effortlessly. Deliverables for this project include a functional prototype that integrates all electrical and mechanical components, an installation plan detailing the optimal location and mounting strategy, and a user manual designed for simplicity, enabling TAs and staff to operate the display software effectively. Students will utilize various shop spaces in the development of their prototype, including the woodshop, metalshop, additive manufacturing, and EE/IOT spaces.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Penn State Learning Factory Tourbillion Clock Design and Manufacturing Banyay, Greg 0 0 0 0 0 3 0 0 0 3 2 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project focuses on the redesign, prototyping, and manufacturing of a functional 3-axis tourbillon clock. While there are many readily available 3D-printable models to serve as a starting point, it's important to recognize that the tolerances of 3D printed components differ significantly from those of machined parts. The first step in this project is to adapt the existing design to meet the precise tolerances required for machining, which involves creating and testing multiple prototypes of key components to validate the design and manufacturing process. The second step is researching and selecting the appropriate metals based on the specific requirements of the components and the clock's performance. Finally, the project culminates in the precise manufacturing of a fully functional, time-accurate tourbillon clock.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Third Thought 1 Pneumostylet - Team 1 Lei, Yuguo 0 0 0 0 0 0 0 0 1 0 2 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Accurate and rapid placement of a breathing tube in the trachea is important. The pneumostylet will aid this process by enabling the medical practitioner to better guide the breathing tube into the correct location.

There are two components to the single device. The first component, the handpiece, is held in the hand and, depending upon the strength of the grip compression, generates and removes pressure. The pressure is transmitted to the adjoined second component, the stylet, which is a 14 inch straight but flexible tubing with pockets over the bottom 5 inches. In practice, the stylet is first inserted inside the breathing tube (like the lead in a pencil), and when the handpiece is compressed, the pockets of the bottom inches of the stylet inflate, creating a more or less angled "J" shape. The tip of the breathing tube (which is overlying the stylet) is placed in the trachea, and the pneumostylet is removed.

This polymer device must be 100% elegant, reliable, intuitive, and easy to use. Handpiece: create and remove pressure, deliver and remove 20 ml of air or fluid. Stylet: create "J" shape (and return to straight) overlying breathing tube with correct sequence of angulation.

While the prototype creation is the centerpiece of the project, there are many other critically important features which need to be addressed such as how it will be manufactured, packaged, and FDA approved (510K process).
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Third Thought 2 Pneumostylet - Team 2 Medina, Scott 0 0 0 0 0 0 0 0 1 0 2 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Accurate and rapid placement of a breathing tube in the trachea is important. The pneumostylet will aid this process by enabling the medical practitioner to better guide the breathing tube into the correct location.

There are two components to the single device. The first component, the handpiece, is held in the hand and, depending upon the strength of the grip compression, generates and removes pressure. The pressure is transmitted to the adjoined second component, the stylet, which is a 14 inch straight but flexible tubing with pockets over the bottom 5 inches. In practice, the stylet is first inserted inside the breathing tube (like the lead in a pencil), and when the handpiece is compressed, the pockets of the bottom inches of the stylet inflate, creating a more or less angled "J" shape. The tip of the breathing tube (which is overlying the stylet) is placed in the trachea, and the pneumostylet is removed.

This polymer device must be 100% elegant, reliable, intuitive, and easy to use. Handpiece: create and remove pressure, deliver and remove 20 ml of air or fluid. Stylet: create "J" shape (and return to straight) overlying breathing tube with correct sequence of angulation.

While the prototype creation is the centerpiece of the project, there are many other critically important features which need to be addressed such as how it will be manufactured, packaged, and FDA approved (510K process).
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
TMP Manufacturing Comapany, Inc. Plant layout Expansion Zajac, Brian 0 0 0 0 0 2 0 0 3 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

We have attached the drawing for the current plant layout and the expansion. We are looking to move raw materials from the main building to the new expansion. The new addition is being constructed on an existing outside pad with a significant slope. The object is to maximize both storage and improve the flow inside the current plant.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
US Silica Mapleton Depot Automate the process of opening, closing, and sealing of rail car hatch lids for the health and safety of workers. Lewis, Alfred (Scott) 0 0 0 0 0 0 0 0 3 2 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Improve worker health and safety though automation of rail car loading practices.

Operator health and safety may be unnecessarily placed at risk with current rail loading procedures.

The present situation exposes operators to fall risk from working at heights, in addition to potential for exposure to the respirable health hazards of the products being loaded. To mitigate the risks, workers must wear fall protection PPE, in addition to respiratory protection, during the present process of bulk loading rail cars.

The present process involves the following general steps:
1. The operator advances an empty railcar into the loading area. (Remote via a
Trackmobile)
2. The operator dons fall protection harnesses, SRLs, and a respirator in addition to
their normal PPE to enable safe access to the top of the railcar.
3. The operator then boards the car top, unseals, unlatches, and opens a loading
hatch, then returns to the control room.
4. From the control room, the car is moved into position under the fill spout and that
hole is loaded.
5. Once full, the car is indexed to allow that hatch to be closed, locked, and sealed
and the next hatch opened.
6. The operator once again returns to the control room to advance the car and repeat the filling/latching/opening process until all the hatches of the given car are full.

It is desirable to remove the operator from the potentially unsafe area entirely by allowing them to perform these process steps either automatically or semiautomatically from a remotely located control room environment. The operators presently can move cars and fill openings from a control room.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Volvo Group Trucks & Technology Rapid Bolt Tester Wang, Chao-Yang 0 0 3 3 0 3 3 0 3 2 3 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This outcome of this project would be a rapid test bench setup that can compare the behavior of different fasteners (A:B comparison) in under 10 minutes. Key measurements include torque, angle, and load.

The problem this project addresses is reducing the time required to obtain information to make sound engineering decisions on continued usage of parts.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Washington Suburban Sanitary Commission Universal Service Connection Device Wang, Chao-Yang 0 0 0 0 0 3 3 0 0 2 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The WSSC Water is a bi-county, public water/wastewater utility in Maryland that was established in 1918. For over 100 years, WSSC Water has served the communities of Prince George’s and Montgomery counties providing life-sustaining water and water resource recovery services to individuals, families and businesses. WSSC Water maintains and repairs approximately 12,000 miles of buried pipes and several dozen facilities to provide water services to its community. WSSC Water provides potable water to its customer through what is called a “service connection”. Within our system, WSSC Water has approximately 2 million service connections!

Service connections are made of thick wall copper tubing. Depending on the house or office building the size of a service connection can very between ¾” to 2” in diameter. These connections a buried underground at a depth of approximately 6 feet. When installing this connection a field crew must bend, shape, and align the copper tube with the water main. In addition, then service connections leak or break, the copper tube may become pinched and need to be “re-rounded”. This is a highly labor-intensive process and current tools to perform this work are inadequate. WSSC Water needs a better tool – something that is very durable, provides great leverage for the field technician and something that is adaptable for varying tubing sizes.

The PSU teams will design, develop, and prototype a devise that would meet all of the above requirement and incorporate ergonomics aspects to make the process of using the devise the most comfortable for the field Technician. With approximately 2 million service connection to deal with, this is a very common and frequently executed job. The devise will need to be durable, portable and as light weight as possible. Additional feature for performing this job during the night would be very helpful as WSSC Water works around the clock.

The PSU team will have freedom to develop concepts of solutions starting at day 1 of the project. A site visit in the first few weeks will also highlight actual working conditions.

The project will allow WSSC Water to continue to provide a highly reliable water source to approximately 2 million customers by allowing WSSC Water employees to install and make repairs as quickly as possible and move on to serving the next customer.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
WaveBreaker Technologies LLC WaveBreaker Technologies: Small Scale Production Plan for a Modular DryBox Zajac, Brian 0 0 0 0 0 3 0 0 0 1 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

This project builds on recommendations from a Learning Factory Capstone project completed in FA24. That project created two 3D-printed prototypes proving we could create a watertight box that mounts quickly to a kayak.
This semester's project will focus on creating and testing a small-scale manufacturing process plan. At this time, we assume we can utilize a low-pressure plastic epoxy injection molding process. To complete this project, students will prove or disprove this assumption, reconfigure CAD files to suit manufacturing requirements, create a mold, test the manufacturing process, and record a manufacturing process plan for small-scale production.

Key Deliverables:
Develop a small-scale manufacturing process plan.
Produce a fully functional unit utilizing the manufacturing process plan.

Stretch Goals:
Medium/Large Scale Manufacturing Process Plan
Manufacturing Process Plan for modular inserts/attachments

Note: To ensure students are equipped with the necessary skills for design and manufacturing tasks, we ask that the following training be completed at the Learning Factory by Week 3 of the project: Basic Saftey, Additive—Basic I, Basic II, Advanced and 2nd and 3rd Floor Makerspace.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Well Master Corporation Lubricator Lifting Device - SJTU Global Project Neal, Gary 0 0 0 0 0 0 0 0 0 2 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Description:
- Well Master dimensionally inspects every lubricator that comes into our facility from our vendors. This requires that each lubricator be lifted out of the crate, set up vertically on the floor and then placed horizontally back into the crate.
- Lubricators are heavy and because of their size they are difficult to lift and move safely.
- This project is to design a fixture that can be attached to a fork-lift to securely grab the lubricators lift them out and rotate them into a vertical position.
- The current method of doing this involves using lifting straps and multiple people to orient the lubricator.

Success Criteria (Goals):
- Design a fixture that can lift and hold a lubricator securely and safely.
- Fixture should slide onto the forks of a forklift and attach in a way that prevents slipping off the forks. A standalone device can also be considered but may add to the complexity of the design due to the weight of the object being lifted.
- An ideal setup will allow a 200-pound lubricator to be picked up out of a wooden crate (40”W x 20”L x 20”H) and then rotate from a horizontal orientation to a vertical orientation.
- If possible, build and test the concept in Changzhou China at the current manufacturer and a second unit that can be used in Golden, CO.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Westinghouse Air Brake Technologies Corporation (aka Wabtec) Blower Impeller Cast to Composite Banyay, Greg 0 0 0 0 0 0 0 0 0 0 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Overview:
- The Propulsion engineering team has a field proven axial impeller design w/ 15+ year application success. However, we would like to evaluate non-metal options to reduce with weight and cost.
- This blower is used in locomotive and off highway vehicles applications.
- Impeller is ~2’ in diameter and operates at speeds up to 4000 RPM
- Target application life is 20+ years.
- Airflow, noise and reliability are critical to impeller success.

Problem Statement:
- Analyze and provide alternative material proposals that achieve performance and cost targets.
- Project should include FEA & CFD including stress, deformation to confirm proper airflow delivery/structural acceptance.
- Recommend validation activities for design demonstration
- Analysis must consider all application needs – duty cycle, speed, shock, thermal, UV, wash, etc.
- Solution must be retrofittable and operate successfully on existing blower assemblies (shaft/contravene).
- Design should consider balancing techniques
- Stretch Goal - identification of manufactures with experience in similar products that can quote impeller development. Financial targets not to be shared with potential vendors.
- Stretch Goal – review rupture containment strategy to reduce contravene ring thickness.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Westinghouse Air Brake Technologies Corporation (aka Wabtec) Determination of Bolted Joint Characteristics Banyay, Greg 0 0 0 0 0 0 0 0 0 0 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Overview:
- Bolted joint behavior is heavily influenced by a variety of factors including the load vs torque relationship of fasteners and the phenomenon of embedment – relaxation of the joint materials after initial joint tightening which reduces loading within the joint.
- It is proposed to develop test methods using hardware to study the effects of various bolted joint components on the embedment of a variety of common materials used in our products, and also to study the behavior of various locking nuts and their torque characteristics.
- This study will involve developing a working knowledge of bolted joint behavior, related joint calculations, and developing instrumented bolted joint assemblies from which to empirically derive joint characteristics.

Problem Statement:
- Determine through test methods the joint embedment of bolted joints with the following components in the grip:
-- Painted sheet metal
-- Zinc plated sheet metal
-- Painted and plated aluminum sheet
-- Tin plated copper
- Determine the embedment of flat and lock washers, and dependency on applied preload
- Determine average and standard deviation for joint nut factor for zinc plated hardware using prevailing torque nuts
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Westinghouse Air Brake Technologies Corporation (aka Wabtec) Multi-Vehicle Energy Transfer Arc Flash Hazard Analysis Cubanski, Dave 0 0 0 0 0 0 1 2 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Overview:
- Arc-Flash occurs when a short-circuit event has sufficient voltage and current to allow current to flow through ionized air.
- Two points with voltage potential may be bridged temporarily by a conductor. That conductor could be a small piece of wire, a cable, or a tool, that is then either melted or blown away, forming an arc.
- An Analysis must be performed for any component or cabinet where HV points are present that have sufficient current capability to result in an arc-flash.
- Anytime a connection is made where a fault down-stream could result in an arc-flash the incident energy must be calculated.
- Arc Flash Analysis is performed following NFPA 70E 2015 Annex D.5, using assumptions to be provided by Wabtec

Problem Statement:
- Determine the PPE, and Arc-Flash Working Boundary for battery electric vehicle external connections
- Provides values to put on arc-flash hazard labels that are placed on the exterior of all cabs where Arc-Flash hazard may exist
- Provide any further recommendations (fusing, additional isolation needs., etc) based on the analysis results
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
York Precision Machining & Hydraulics Multi-discipline Engineering Capstone Project: Developing Portable/Compact Power Unit for Remote and/or Mobile Hydraulics Applications Using Bear-Loc® Load-Holding/Locking System Zajac, Brian 0 0 0 0 0 0 0 0 0 1 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Participants in this Capstone project will have the objective of developing a portable/
compact hydraulic power unit to provide hydraulic power to the manufacturer’s proprietary product, Bear-Loc, for use where there is no hydraulic power available. Bear-Loc is known for its superior safety and performance in hydraulic load holding and locking. The Bear-Loc could provide useful for many industries and applications that are currently prevented from using it because of lack of power in remote locations.

The successful portable/compact hydraulic power unit will displace a small amount of fluid i.e. just enough to operate our Bear-Loc® no matter where it is located. In theory this unit would contain its own power source, some sort of small compressor and perhaps an intensifier unit to provide the pressures needed, as well as a small reservoir to hold additional hydraulic fluid. It should be small enough that it can be moved and operated by one man without assistance. This design may even be taken one step further to contain a manifold to which hydraulic lines could be attached if the unit is powerful enough to displace a larger amount of fluid or move a small actuator. It could also contain sensors that would read current pressures, indicate when the desired pressure has been reached, and display whether the lock is open or closed. There would also be design considerations such as being sufficiently robust to stick with our core values of offering a quality product, yet not so costly to manufacture that it is out of budget for potential future buyers. Successful “proof of concept” development of the power unit will become part of the company’s intellectual property.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
ZAP Engineering & Construction Services, Inc. Milling System Sound Energy Generator Eser, Semih 0 0 0 0 0 0 3 1 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

One common method of grinding materials into a fine powder, such as clinker into cement, is to use a piece of equipment called a ball mill. A ball mill is piece of rotating equipment that has a horizontal hollow cylindrical shell with the inside containing various size solid metal balls. As the mill rotates the balls are lifted by shell liners and dropped on top of each other. This function creates a high amount of friction between surfaces and the rock materials are fed into one end of the mill and pass through the cascading balls to be ground into a fine powder and exit on the opposite end of the mill. The grinding action in a ball mill creates a large amount of noise from the rotating metal to metal contact of the grinding media and this requires the entire milling area to require double ear hearing protection for all individuals present in the area. There is an opportunity to design a noise absorbing and cancelling system to protect personnel as well as to convert the sound energy into electricity using the piezoelectric effect. The project will include determining the amount of sound energy that can be captured, designing an enclosure to capture the energy and act as a sound deadening to the outside area, and evaluating potential uses for any energy that can be generated.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
ZAP Engineering & Construction Services, Inc. Mineral Processing Thermoelectric Power Generator Eser, Semih 0 0 0 0 0 0 3 1 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

In mineral processing systems, heat is often a main driver in the chemical processes that are taking place. The heat being generated for the process is contained within mechanical equipment that serves as a way to transport and interact with the materials to attain the desired process results. The design of this equipment requires refractory linings to protect the steel casings of the equipment as well as to retain the heat within the system. This design philosophy creates an opportunity to capitalize on the required mineral processes and utilize the thermoelectric effect to generate electricity. The thermoelectric effect can generate electricity by direct conversion of temperature difference into electric voltage. By designing the refractory lining to accommodate a material on the hot face to heat up compared to the cold steel casing, it can provide a constant temperature differential during operation that can be used to generate electric energy. The systems in question are typically large scale that offer a lot of surface area to install upon. The project will explore the design of components, energy capacity produced and potential uses.
 
 

About

The Learning Factory is the maker space for Penn State’s College of Engineering. We support the capstone engineering design course, a variety of other students projects, and provide a university-industry partnership where student design projects benefit real-world clients.

The Learning Factory

The Pennsylvania State University

University Park, PA 16802