Current Projects

Fall 2025 Projects

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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
AgriPods Development of a Extrusion Process for Starch-Montmorillonite Composite Foam Pellets as Sustainable Soilless Growing Media Kimel, Allen 0 0 0 0 0 0 0 0 3 0 1 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

There is a critical need for sustainable biodegradable growing media for improved soilless plant production. Land availability continues to decline with a growing population which requires more quality food products. The properties of available soils continue to degrade including reduced organic matter, unfavorable pH, increased salinity, exposure to harmful chemicals, decreased fertility, and poor structure. Soil also requires maintenance and does not offer precision control over nutrients and water retention. Available alternatives including peat, coco coir, perlite, vermiculite, rock wool, foam-based materials and others suffer from significant issues such as sustainability including end of life disposal, biodegradability, mechanical properties, water retention or aeration limitations, or cost.

To address this need, a new stable insoluble compostable soilless medium based on starch-montmorillonite composite foam pellets has been developed. It is currently manufactured in the lab using a hand molding and microwave expansion process. To manufacture in volume, a production extrusion process is needed. Specifically, an extrusion process needs to be developed that mixes the ingredients, gelatinizes the starch, raises the temperature to convert water to steam, extrudes the mixture through a die and chops the extruded material to allow subsequent immediate expansion into a spherical pellet. This kind of process is used to make common cereals like Kix.

The goal of this project is to develop a soilless media production extrusion process using the PSU Berhend Plastics Production Laboratory (PPL). The team will have to examine the literature and develop a design of experiments to be performed in the PSU PPL. Multiple iterations will likely be needed. Final materials will need to be characterized for porosity, stability and water retention characteristics.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Artful PM LLC Concept Development: Technical Design for Smart Shoes to Detect Obstacles and Uneven Surfaces to Help Prevent Falls Menold, Jess 3 0 2 0 0 0 0 0 0 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Diverse groups of people, particularly the elderly, visually impaired, or individuals with balance or mobility challenges, may be prone to an increased risk of falling. It is proposed that a Smart Shoe could be developed using current state technologies. This footwear would incorporate electronics to proactively detect obstacles and uneven surfaces in real-time and provide immediate feedback to a wearer’s companion device, reducing the risk of falls and related injuries.

The design would need to integrate a system of miniature sensors embedded in the front and sides of the shoes. These sensors, including ultrasonic or infrared proximity detectors, could continuously scan the environment for objects or uneven surfaces within a predefined range. The shoes could connect wirelessly to a companion device.
When an obstacle is detected, the system triggers a warning mechanism to the device to alert the user. Feedback to the user could be provided in different ways – e.g., visual and / or auditory alerts received via a smartphone app or a smart watch, color changes or electronic vibrations received via an electronic bracelet, auditory alerts or color changes received via smart eyeglasses or hearing aids.

An app can also allow users or caregivers to monitor walking patterns, configure sensitivity levels of the sensors, and receive alerts about potential risks in real-time. The electronic bracelet could function as a simplified alternative for users who may not use smartphones, delivering alerts through lights, vibrations, or sound.
The app interface should be designed to be user-friendly, offering features such as real-time obstacle detection visualization, step counting, location tracking via GPS, and fall history analysis. It can also notify caregivers in case of a detected fall or if the user deviates from a set walking route. Additionally, data collected can be used by healthcare professionals to assess gait stability, predict fall risks, and tailor interventions accordingly.

From a wearer’s perspective, the shoes should maintain a stylish, contemporary design, ensuring users do not feel stigmatized by wearing assistive devices. The electronics could be embedded in a lightweight, shock-absorbing sole to maintain comfort and minimize bulk. A rechargeable battery could be concealed in the heel, offering several days of operation on a single charge, with wireless charging capabilities for convenience.

In conclusion, this design concept would offer wearable electronics with practical footwear to create an intelligent system that enhances safety and mobility. The next step is to create a set of specifications for this product that can be used to apply for a patent from the USPTO.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
B. Braun Medical AI website Optimizing a list of potential Obsolete Part Replacements to enable sustainment of Manufacturing Continuity Ward, Robert 0 0 0 1 0 0 0 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)

Input: Enter open AI interface into website to search predefined input fields including Manufacturing equipment type, Part description, Original Manufacturer, Part number/Model, imagine section to take picture of part, and optional Product Name/Lineup.

Results: Original part description as well as technical specifications and dimensions. As well as a price and link to purchase if applicable. Two potential replacement parts for further evaluation and eventually possible replacement parts. Along with why it could work as a possible replacement and a price and purchase link to the potential replacement parts.

Reference: You are now a professional reliability and maintenance engineer congratulations on your promotion. from now on here is what I want you to do: I am going to provide you with a machine, a part from that machine, the original vendor of the part, and the part number. What I want you to do is Research the original product: Find the official product page (even if it's archived or marked as discontinued). Gather all available technical specifications, dimensions, features, and original pricing. Then I want you to find me an overflow website, I want to know where I cam purchase the exact product online right now. When you find that I want you to list for me the Vendors name, the cost of the part, and give me the link to where I can buy it. Then, I want you to use the same specifications to find a new part that could act as a replacement part. I want the specifications to be very similar but not exactly the same. I WANT TO SPECIFY DO NOT GIVE ME AN OVERFLOW WEBSITE WITH THE SAME EXACT PART AS A POSSIBLE REPLACEMENT PART. When you find 2 possible replacements, I want you to list the following Replacement part number Replacement vendor Cost or replacement part 2 bullets on similarities between specs and why the part would work as a replacement The link to the replacement part I want to stress that I want 2 possible replacements so I should see all those things for 2 possible replacements. Let me know if you have any questions and do not assume If a part is custom simply say custom part. If you cannot find the part anywhere, say that too do not just give me a random part. ok remember, your job as the engineer is to research and remember the specifications that you find from the original product (that's why I have you give me that) and then find the same part (overflow link to buy the original) and then compare it and find a similar, but not the same part (2 possible replacements) got it?
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: YES

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.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Dana Incorporated Smart VPN Tunnel Manager Ward, Robert 0 0 0 1 0 0 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)

Problem Statement:
As a Tier 1 supplier, Dana Incorporated relies on hundreds of VPN tunnels to securely deliver products and services to its global customers. Managing these tunnels manually across a complex, distributed environment is time-consuming and resource-intensive—especially for lean infrastructure teams. This project challenges senior engineers to design and implement automation that streamlines VPN tunnel inventory, monitoring, and configuration, enabling faster response times, improved reliability, and scalable operations.

Benefits:
Increased Operational Efficiency
Automates repetitive tasks like tunnel inventory and configuration, freeing up engineering resources and accelerating response times.
Scalable & Consistent Management
Standardizes tunnel setup and maintenance across environments, ensuring compliance and simplifying future growth.
Improved Network Reliability
Enables proactive monitoring and alerting for tunnel health, reducing downtime and enhancing service continuity.

Project Requirements:
All automation is intended to be used for Palo Alto firewalls (PA-460, PA-1410s)
VPN Tunnel Inventory Collector Build a tool to automatically discover and catalog VPN tunnels, capturing key attributes like peer IPs, status, and encryption settings.
Tunnel Health Monitoring System Implement automated checks for tunnel status, latency, and error logs, with alerting/reporting capabilities.
Web-Based Management Interface Develop a user-friendly GUI for viewing tunnel data, filtering by status/location, and initiating basic actions.
Automated Tunnel Configuration Deployment Create scripts/templates to automate tunnel creation, updates, and removal using standardized configurations.
Logging & Reporting Features Integrate logging for all automated actions and generate periodic reports on tunnel health and configuration changes.

Project Deliverables:
Base scope of project is to complete the 5 requirements listed. The focus of the automation
Weekly status reporting and scheduled meetings with program sponsor(s)
Regularly updated project schedule, provided to project sponsors on a weekly basis
In addition to the graphical user interface output, the tool should have capability to provide outputs in the form of flat files (CSV, XML, etc…
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 Rattner, Alex 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: YES

Images and Additional Links (if provided)

The conversion of heat to power (and vice versa) often requires the transfer of thermal energy between fluids without direct physical contact. The devices used for this purpose (heat exchangers) are large, expensive, and are designed with performance constraints on heat transfer and pressure drop. The current state-of-the-art, the diffusion-bonded heat exchanger, has certain performance and cost limitations that could be overcome with additively manufacturing technology. Last semester, a PSU Capstone project investigated design and manufacturing tools in collaboration with the 3D Systems CIMP-3D group, culminating in a conceptual design that offered substantial cost savings and performance improvements over conventional technology. The team built and flow tested a small coupon heat exchanger, which confirmed certain aspects of the design approach. In this follow-on project, the conceptual design will be advanced further using newly implemented capabilities in the nTop design toolkit, and a small-scale heat transfer test will be designed and completed using a polymer heat exchanger. If time and budget permit, a laser powder bed fusion version will be designed and printed for possible follow-on testing.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Entertainment Buddy LLC Development of Assistive Technology for Immobile/ Disabled Individuals in Healthcare Facilities Choi, Kyusun 3 0 1 0 0 0 3 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Entertainment Buddy provides an assistive phone holder for patients and residents in hospitals and nursing homes settings where accessibilities are often overlooked. The assistive phone holder allows users to access their entertainment and contact to loved one hands-free, and maximum the usage of limited spaces.

- Construction of a working physical prototype with correct tolerances
- Materials selection that corresponds with medical field regulations
- Incorporation of smart technology to improve user safety and accessibility
- Perform testing of the prototype
- Development of power supply system for wireless charger
- Development of wireless charger that does not interfere with existing medical devices
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Esotaira Inc. One-Axis Tilt Propulsion System for UAV Thrust Vectoring Mittan, Paul 0 0 3 3 0 0 2 0 3 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

We’re creating a whole new style of flight! This opportunity presents an emergent yet beautiful challenge: Design and prototype a one-axis propulsion actuation system that supports an active propeller. You and your team will design and prototype a compact and lightweight propulsion module that rotates an active drone propeller between zero degree and 90 degree tilt positions. The system must lock securely at target angles and maintain alignment under continuous thrust and dynamic loads. You will engineer the tilt mechanism, integrate a high torque actuator, and develop an electrical interface for power and signal transfer across the rotating joint without cable twisting. The module will be tested on a rig to validate smooth articulation, precise positioning, and stable thrust vectoring. This project lays the groundwork for omni-directional UAV propulsion systems designed for versatille modes of aerial efficiency and maneuverability.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Evet technology Limited Solar powered poultry health monitoring device Choi, Kyusun 0 0 1 2 0 0 3 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Project Overview
Vision Statement
Develop an autonomous, solar-powered poultry health monitoring device that integrates with our existing AI disease detection platform to provide continuous, real-time health monitoring and surveillance for smallholder farmers across sub-Saharan Africa.

Problem Statement
our Current poultry health monitoring relies on farmer-initiated photo submissions through WhatsApp, creating gaps in early disease detection and requiring farmers to actively identify health issues. This reactive approach leads to delayed intervention, higher mortality rates, and reduced effectiveness of our AI diagnostic capabilities.

Solution Approach
Design a weatherproof, solar-powered device equipped with high-resolution cameras, IOT and edge computing capabilities that continuously monitors poultry flocks, temperature, pen condition, processes images locally using our trained AI models, and automatically alerts farmers and veterinary partners when health anomalies are detected via sms or app notifications
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
EvoNatura Integration of Biodegradable Additives into Conventional Polymers Kimel, Allen 0 0 0 0 0 0 0 0 0 0 1 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

This project builds on prior success incorporating a proprietary biodegradable additive into biopolymers. We now aim to expand its application to conventional polymers such as polyethylene and polypropylene. Students will assess additive stability and compatibility under industrial processing conditions, including extrusion and injection molding. The project also includes collaboration with contract manufacturers to optimize formulations for pilot-scale production. Key deliverables include prototype films and molded plastic parts containing the additive, alongside process documentation, test data, and recommendations for commercial scaling.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Exacta Global Smart Solutions Cellular based IoT using oneM2M Choi, Kyusun 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: YES

Images and Additional Links (if provided)

An IOT device that operates far from power and communications infrastructure requires power efficient implementations, reduced complexity and sustainability. This can be achieved by using components that are already known and verified to work so that a developer can quickly bring a new product to market. Cellular devices are an example where the radio module components are formally certified to operate according to specific cellular radio standards. oneM2M is a global standard that serves to make developing IoT applications that can be formally certified as well. ETSI MEC has capabilities to support EDGE computing such that the latency and power requirements are reduced for IoT deployments.
This project will use oneM2M standards to demonstrate compliant IoT systems. We will use Nordic Semiconductor’s Thingy 91X as a part of multiple access gateway to communicate to the cloud.
The project team will be exposed embedded development, global IoT standards and have the potential to participate in global hackathons. The team will learn oneM2M application development and embedded device programing using the Nordic Thingy 91 and Zephyr RTOS. The main deliverables will be: See image
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Fleet Equipment Corporation / Columbia Industries Tire Positioner Pivot Arm Redesign Rattner, Alex 0 0 0 0 0 0 0 0 0 2 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Background: Fleet Equipment Corporation is a leading manufacturer of tire service trucks. A tire positioner is a truck mounted crane hand used to mount and dismount tires on offroad equipment. Though emphasis is often placed on the maximum size tire a given tire positioner can handle, being able to gasp smaller tires is also important.

The tire positioner clamping mechanism is a four-bar linkage design actuated by a hydraulic cylinder. Currently on the 108 and 130 tire positioners, the hydraulic cylinder is pinned to ears on the side of arm weldment. The 147 tire positioner pivot arm has been redesigned so the hydraulic cylinder is attached with the same pins as the arms. The changes to the 147 allowed for a longer cylinder stroke which closes the hand farther. This project is to determine if the 108 and 130 arms can be redesigned in a similar manner.

Key Design Components:
1. Mount to existing main frame and clamp arm weldments to allow older units to be retrofitted.
2. Decrease weight when possible.
3. Design with cost in mind.

Deliverables:
1. Basic study of current 108 and 130 pivot arm designs including clamping geometry, clamping force, and finite element analysis.
2. Drawings, clamping geometry, clamping force, and finite element analysis of proposed designs including any major design iterations.
3. If designs are determined to be feasible, FEC will work with students to produce a prototype of one of the arms.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Foster Exploration & Production II, LLC Digital Quarry Operations: Automation and Optimization for Aggregate Production in Puerto Rico Wang, CY 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)

Project Description: Foster Exploration & Production II is acquiring an abandoned quarry in Yabucoa, Puerto Rico with approximately 2,000,000 cubic meters of granodiorite sand. The quarry will supply critical aggregates to help rebuild infrastructure destroyed by hurricanes. The sponsor seeks innovative solutions to modernize quarry operations through technology integration.

Problem to Solve: The quarry requires operational improvements to reduce costs through automation, minimize equipment downtime through predictive maintenance, and maximize revenue by optimizing product mix for different industrial customers. Students will analyze current quarry workflows, research modern mining technologies, and develop implementable solutions.

Expected Benefits: Reduced operational costs, improved equipment reliability, optimized product allocation, enhanced safety through automation, and sustainable supply of materials for Puerto Rico's reconstruction.

Deliverables: Comprehensive report with recommendations for operational improvements.
Feasibility studies and engineering analysis demonstrating effectiveness of proposed solutions.
Cost justification and economic analysis (ROI calculations).
Implementation roadmap with prioritized initiatives.
Conceptual designs for automation systems and monitoring equipment.
Workflow optimization models and process improvements.
The sponsor will provide remote support via Zoom, site data, equipment specifications, and operational parameters. The quarry is located 15 minutes from the sponsor's residence, enabling on-site data collection as needed.
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, CY 0 0 0 0 0 0 0 0 2 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

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 compressor operating conditions and case sizing, the dimensions of the diffuser can vary in many ways. Different diffuser types can be seen in the figure, such as (a) parallel wall, (b) tapered, and (c) a combination of the two. 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. A morphing geometry to accommodate changes to the shroud side diffuser could eliminate long part lead time, increase testing frequency, and decrease costs.

The engineering team at FOX would be excited to sponsor a team to conduct continued development of a movable diffuser wall insert for the test rig. We are looking for a well-documented and simulation validated design that could be machined by FOX for direct implementation into the test rig. Development of a preliminary prototype and associated documentation can be made available to assist this semester’s project group. Deliverables may include (1) CAD models, (2) Finite Element Analyses, (3) engineering drawings, (4) a prototype to validate mechanics.

Knowledge of turbo-compressors is not required. This is a great opportunity to work on a mechanical design project and gain some insight into the turbomachinery industry, as well as the R&D work we do here at FOX.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Frozone Automated Freeze-Thaw Cycle Control Module for Permafrost Evaluation Mittan, Paul 0 0 3 0 0 0 2 0 1 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

The project aims to address the challenges of evaluating permafrost in Alaska by developing an automated control module. This module will simulate freeze-thaw cycles and monitor the electrical properties of permafrost in real-time. The system will include sensors to measure temperature, moisture, and electrical properties, and will be capable of logging data for analysis. The objective is to create a reliable and efficient tool for researchers to study permafrost dynamics and predict changes due to environmental factors. The project will involve designing the hardware, developing the software for data acquisition and control, and integrating the system components.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Function Focused PMR Care+ Assistive Device for Closing a Winter Coat Menold, Jess 2 0 0 0 0 0 0 0 0 3 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Overview: The goal of this project is to design and build an easy-to-use assistive device that permits a one-handed person to independently zip up/down a heavy winter coat or hunting jacket.

Background: There is no device commercially available that enables a person with only one functional hand to easily and consistently zip up a jacket independently. The need for this device is relevant for individuals who live in cold climates and are unable to close their winter coats without holding the loose ends with their only functioning hand.

Key Design Components: For this device to be useful, it would be helpful to have the following features.
1. Anchoring mechanism for keeping zipper taut
2. Guiding device to bring together the two ends of the zipper
3. Variability and sturdiness for coats of different sizes and/or weight
4. Retractability to reduce size of device after each use for putting in a pocket

Deliverables: The capstone team is expected to work closely with the client and sponsor to design, build, and field test a fully functioning assistive device incorporating the above components.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Harbison Walker - A Member of Calderys Refractory Material Design for Magnetic Separation Kimel, Allen 0 0 0 0 0 0 3 0 0 2 1 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Students will have to develop a test method for measuring the strength of magnetism in fired refractory samples. They will be provided with one source of stainless-steel fibers and will test how the amount of inclusion affects magnetic and refractory properties. After testing students should complete a short literature review based on their experiences to outline other sources for future testing. The literature search should comment on the compatibility of fibers in alumina-silicate refractories.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Hyperion Materials and Technologies Optimization of drill product line at Latrobe PA plant (real business impact & in person visit!) Zajac, Brian 0 0 3 2 0 0 3 0 0 1 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Description:
> Hyperion Materials and Technologies is a global leader in the production of advanced hard materials. We have facilities in 19 countries and have a portfolio of 50K products.

> As part of the capstone project, you will be working on our drill product line within our Precision Solution business, which combines materials science and engineering expertise with manufacturing, grinding, and finishing services to offer precise finished components made from hard and super-hard materials for business application. We produce drill products at our Aggressive Grinding plant based in Latrobe, PA and expect a significant increase in demand, so we are proactively seeking to reduce the current cycle time (i.e. the time it takes an item to complete all production steps) by as much as 50%.

> Achieving this goal is expected to generate substantial cost savings and unlock new revenue opportunities, directly impacting our bottom line and customer satisfaction.

> We would like a team of Penn State students to help us develop a simulation of our production environment to enable the testing and analysis of different scenarios that could reduce cycle time of production. We are open to the students developing various solutions to achieve this, including automation.

> In addition, to testing solutions to reduce overall lead time, we would like the students to research and assess the feasibility and ROI of introducing machine tending automation to centerless grinding machines.

> This project offers a unique opportunity to work on a real-world challenge with tangible business impact. Students will receive hands on experience through visiting the plant, collecting the data required, and building a model from the ground up - contributing directly to the future of our operations.

Deliverables:
> Simulated model of current state
> Scenario analysis and recommendations on an improved future state
> Defined data requirements and data collection approach for simulated model
> A roadmap for future improvement phases
> Market study, recommendation, testing, and economic analysis of machine tending automation
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Industrial Engineer.ai AI-Powered Voice-Activated Glasses for Hands-Free Projects Zajac, Brian 0 0 0 2 0 0 0 0 0 1 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Workplaces like manufacturing floors, warehouses, and distribution centers are filled with hands-on activity — making it hard for frontline workers to take notes, access instructions, or capture observations without breaking their workflow.
This project challenges students to develop and prototype a voice-activated smart glasses solution (e.g., Meta Ray-Bans or an open-source alternative) that allows workers to receive audio-guided training instructions and capture voice notes on the go — all hands-free.

Students will:
Research and select suitable smart glasses hardware with open voice or AI capabilities.
Design a system to capture, transcribe, and organize voice notes or commands from users.
Prototype a workflow where audio prompts can guide users through standard operating procedures (SOPs) or training tasks.
Build a lightweight application or interface to store captured data (e.g., in Google Sheets, Airtable, or a database).
(Optional Bonus) Enable real-time transcription and summarization of observations using foundation models (e.g., Whisper, Gemini, Claude).

This is a an opportunity to combine AI, wearable tech, and industrial operations to solve challenges in training and knowledge capture.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
International Society of Service Innovation Professionals Exploring Synthetic Data for Service System Innovation 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 goal of the project is to help ISSIP leadership explore the benefits and challenges of synthetic data for service systems innovations using multiple modern AI tools at each step. For example, a major challenge in academic-industry collaborations is the need to exchange confidential or proprietary real-world data sets. How might synthetic data be used instead? The deliverables will include: (1) start plan, (2) multiple (at least 3) case studies of service system innovations with an associated synthetic data set produced by a system-process-model to be uploaded to GitHub, (3) final whitepaper (title page, abstract, introduction (problem & importance), approach, progress, concluding remarks & future directions, acknowledgements, references), (4) final presentation with team picture, (5) project poster, and (6) recording of team delivering the final presentation.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Kitron Technologies, Inc. Robotics and Automation for Electronics Manufacturing Zajac, Brian 0 0 3 2 0 0 3 0 0 1 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Kitron Technologies is a global Electronics Manufacturing Services (EMS) company with a facility in Windber, Pennsylvania that supports high-reliability products in defense, medical, and industrial sectors. Kitron is seeking engineering students to help explore and prototype robotics and automation solutions for a new electronics production line.

The goal is to improve efficiency, increase throughput, and enhance quality across several key manufacturing steps. These include bulk component sorting and staging, robotic placement of components onto printed circuit board assemblies (PCBAs), 2D/3D visual inspection, automated loading/unloading between machines and conveyors, adhesive application, and final packaging. Students will need to consider challenges such as handling heavy or delicate boards, managing small components with tight tolerances, and designing adaptable systems for multiple product types.

By the end of the semester, teams will deliver a report that includes a market study, technology selection, feasibility testing (virtual or physical), and a cost-benefit analysis. Most solutions are expected to use commercial-off-the-shelf hardware and software, with some opportunities for applied research in machine vision and robotic integration.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
LEMIAMER Drywall Lift For Rolling Scaffolding Wang, CY 0 0 0 0 0 0 0 0 0 0 0 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Commercially available drywall lifts are capable of lifting sheets of drywall to the underside of a level or pitched ceiling. The problem with those lifts is that the installer must work around the lift in order to install the sheet of drywall. This capstone team would design and prototype a drywall lift that connects directly to the end ladders of rolling scaffolding, thereby allowing the installer to stand on the scaffolding platform to install the fasteners easily. The system should have an automatic locking system so that a single operator can lift the sheet of drywall by themselves and allowing for hands free work for fastening the drywall. A manually operated brake release is needed to lower the drywall supporting rails once the sheet of drywall has been secured to the ceiling joists. This lift should also be designed so that the operator can break it down for easy transport and storage.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Lockheed Martin Tracking Gimbal for Aerial Demonstrations Mittan, Paul 0 0 2 3 0 0 3 0 3 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Lockheed Martin uses a variety of sensors and tracking equipment to monitor developmental aircraft undergoing test flights. Information collected fuels the engineering teams as they pursue advances in aviation. Technology used during testing ranges from handheld cameras to million dollar tracking systems. To support demonstrations within line of sight, we are partnering with PSU to develop a semi-automated tracking gimbal to aid our videography team. The gimbal system is planned to mimic the inputs of a videographer – point camera, adjust zoom, adjust focus, capture image – with an electromechanically controlled system . Students will integrate an off the shelf mirrorless camera into a gimbal system capable of aiming the camera at the test aircraft. The system will follow the aircraft using known GPS points & altitude and provide a stable base for filming aerial demonstrations. Actuation features will be used to adjust camera zoom and other functions to create a high quality shot. When the gimbal system is not being fed live GPS data from the test aircraft, the videographer will be able to control the gimbal via joystick. This setup will provide a stable base for capturing test flight footage while reducing operator fatigue from holding a ~5 lb camera. This project will be a multidisciplinary project requiring team with software, electrical, testing, and mechanical skills to be successful.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Montana State University (MilTech) Next Generation EMP Survivable Equipment Case - Phase II Mittan, Paul 0 0 0 0 0 0 2 0 3 0 1 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Phase II Objectives: With a focus on Material Science and Electrical Engineering (Electromagnetic Pulse Survivable), the Capstone Team will review Phase I design as a basis for Phase II design, prototyping, and testing of a low cost, lightweight, transportable, electronic pulse protection survivable equipment case.

Overview: This a continuation of a Spring 2025 Capstone Project. This phase focuses on material science and electrical engineering for the design of a 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) Physical Samples of innovative and unique materials to be used in future prototypes of electronic pulse protection survivable equipment case to transport defined military equipment.
(1) Written report (electronically delivered) covering the following:
(a) Executive Summary
(b) Overview of Phase I (Original Spring 2025 project)
(c) Custom Designed Case (Material Focus):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. Note: The generation of samples of materials is a higher priority than complete case prototyping.
(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 each material and associated characteristics, the design process, testing event(s), and final result.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
MSA Safety Inc. Assembly Department Materials Replenishment Strategy Zajac, Brian 0 0 0 0 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)

MSA Murrysville currently uses several replenishing strategies for manufacturing components in work cells. G1 Electronics utilize stock transfer reports. G1 pneumatics utilize warehouse management with control cycles and transfer orders. There are also several instances of using a manual, “bulk” replenishment strategy in both areas. G1 pneumatics also house non-replenishable kanbans (NRK).

Warehouse management with control cycles and transfer orders are the preferred method for replenishment. Stock transfer reports require much more inventory on-hand in the work cell and surrounding RIP racks. G1 Electronics should be migrated to this module.

In addition, G1 pneumatics bin quantities and labeling have not been updated in several years. Vendors have changed their packaged quantities which has caused more burden on the “detrash” department. Existing WM control cycles and bins need to be re-evaluated and updated to match current operating conditions.

Students will be expected to 1) evaluate methods of current materials management process and establish “best-practice” future state; 2) establish future state kanban levels based on incoming demand, replenishment lead time, historical supplier performance, and other considerations and 3) recommend future state inventory levels to support demand in sub and final assembly areas to optimize raw and WIP inventories.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Mustard Seed Communities Identifying & Solving Communication & Reporting Barriers at Mustard Seed Communities Jamaica Zajac, Brian 3 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: YES

Images and Additional Links (if provided)

Mustard Seed Communities International (MSC) is an international non-profit organization dedicated to caring for the most vulnerable populations throughout Jamaica, Nicaragua, Dominican Republic, Zimbabwe and Malawi. Founded in 1978, MSC provides loving and lifelong care to over 700 children and adults with disabilities, children affected by HIV, and young mothers in crisis.

In Jamaica, Mustard Seed Communities cares for over 450 children and adults with
disabilities, children affected by HIV, and teenage mothers in crisis. We operate thirteen residential homes, located in Kingston, Spanish Town, Montego Bay, Moneague, Mandeville, and Murray Mount.

There is a consistent problem with breakdowns in communication and reporting across multiple functions areas. MSC seeks support with the following problems:

1) Caregivers providing daily medical care to children with disabilities do not complete the daily medical notes required. This can lead to a lack of continuity in care and lack of progress for the residents. Why?
Desired deliverable:
Survey of caregivers to accurately understand the barriers.
Suggestions for Training/Incentives Needed
Accountability structure

2) 24 hours staffing is required to care for the children with disabilities. Even when staffing levels appear high enough to meet the needs there are always challenges with having enough staff with the appropriate skills at the right time.
Desired Deliverables:
Survey of both caregivers and administration to understand why this is happening
Recommendation for processes such as time off requests or cross training needed
Suggestion for tool to help with scheduling

3) At MSC's largest location there is not a way to report repairs needed or breakdowns to equipment. There is no clear reporting structure, budgeting structure, or point person responsible.

Desired Deliverables:
- Understanding of current scope of problem. What are the biggest issues? Then prioritize
- Determine tool for reporting and budgeting purposes
- Determine incentives to make sure it is used
- Determine who is accountable for making it happen

You can learn more about this amazing organization here: https://www.youtube.com/watch?v=Eg9AvMKsZd4
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 End of Arm Tool for Automated Projectile Handling Rattner, Alex 0 0 3 0 0 0 2 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Currently the loading of large caliber ammunition is a labor intensive process. Sailors are required to manipulate and transport heavy components in order to keep the system loaded. A compatible effector is needed to enable further automation research. The team will come up with a robotic device that can manipulate a projectile, including retrieving it from inventory and placing it into a loading system. Desired deliverables are a design review and prototype effector.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Northrop Grumman Measuring radar waveguides Wang, CY 0 0 0 2 0 0 0 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Students will work with Northrop Grumman Engineers to research and develop a functional solution to mechanically measure waveguides for the TPS-78 radar. Waveguides are precision structures used to direct electromagnetic waves with minimal loss. Tight mechanical tolerances require careful measurement of each waveguide produced by the manufacture. Deliverables will include the measuring tool, associated software, and a final report and presentation justifying their engineering decisions. Included with the proposed solution, students will deliver documentation to operate and trouble shoot the tool in the event of failures. Solutions can include new design for a custom measuring device, identification and procurement of a commercial tool, or other ideas to streamline the inspection process. If a solution requires custom software, students would be expected to provide, at minimum, a working proof of concept. Additional deliverables include a project report detailing the process the group took to arrive at the final solution. Students should have a strong understanding of concepts from a variety of backgrounds. Possible solutions will require mechanical design, electrical design, software design, and manufacturing knowledge.

You can see the radar here: https://www.northropgrumman.com/what-we-do/mission-solutions/radars/an-tps-78-advanced-capability-multi-mode-radar-mmr
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Potain Tower Cranes & Autodesk Reinforced Mast Section for Tower Cranes Rattner, Alex 0 0 0 0 0 0 0 0 3 2 3 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

Potain is a leading manufacturer of tower cranes including hammerhead, luffing, and self-erecting models that are used on construction projects around the world. Potain also provides engineering support for contractors to ensure that their Potain tower cranes are properly erected every time. Autodesk is a global leader in software solutions for the architecture, engineering, construction, manufacturing, media, and entertainment industries. Autodesk’s innovative products and services enable professionals to design, visualize, and simulate their ideas, bringing them to life with greater efficiency and creativity.

This project is a joint project, where the students will work on an engineering problem that Potain is currently facing, while using Autodesk software solutions to design, simulate, and predict structural outcomes. If needed, training and Q&A sessions on Autodesk software solutions such as Fusion and Generative Design will be available to this team.

Background:

A tower crane can only stand so tall before the vertical mast sections can no longer tolerate more bending stresses that are induced by the wind and lifting of loads by the crane. When this limit is reached, the tower crane must be “tied in” to the building or structure that it is constructing. This is accomplished by placing a collar (a reinforced boxed structure) around the vertical mast and then connecting the collar to the building by means of three struts. This connection provides the vertical mast sections of the crane with horizontal support and reduces the bending stress in the mast sections. The mast sections are square lattice structures, comprised of strong cords in the corners and smaller lacings connecting the cords. Because of this design, the mast sections are lightweight and strong against vertical compression forces, but the mast doesn’t have uniform strength against horizontal forces. The strongest points on the mast, with respect to horizontal forces, are at the nodes where the lacings intersect the cords. Since the mast sections have natural strong points at the nodes, a collar can only be placed at those nodes. This can pose an issue for the constructors of the building, because a node on the mast section will not always line up with a floor of the building, which is where the struts are typically connected to the building. This means that they need to build reinforced pedestals on the building floors to come up to the height of the strut, which adds extra cost to the building project.

Problem:

The students will be tasked with analyzing a current mast section that Potain manufactures to determine the horizontal load carrying capabilities of the mast section. Then, with that information known, the team will be asked to design a reinforced mast section that will be able to withstand a prescribed horizontal load (the maximum load supported by the collar) at any point along the mast section. The team should also consider manufacturability in their design. This new reinforced section will allow the builders to place a collar directly in line with a floor and reduce complexity of using a tower crane. The student team will utilize Autodesk software solutions to design, simulate, and predict structural outcomes.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Proportion-Air 1 An Intrinsically Safe Electro-Pneumatic Pressure Transducer with a barrier Cubanski, Dave 0 0 3 0 0 0 1 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Intrinsically Safe devices are engineered to operate in areas classified as a ‘hazardous area.’ This means that the environment or atmosphere in the area is flammable/explosive. The device must be designed in a way that it cannot create a spark and ignite the atmosphere.

Proportion-Air is planning to make our DS Series pressure transducer intrinsically safe (I.S.). We have already received an I.S. rating for our QB Series electro-pneumatic controller. Since the DS Series transducer is often used as a secondary loop to enhance accuracy and response time, we aim to ensure it is also certified for intrinsic safety when used alongside the QB unit.

This project will involve modifying the DS Series circuit board to meet I.S. requirements and documenting all necessary compliance and certification processes.

Picture 1 is a ISQBX intrinsically safe electro-pneumatic controller that is currently I.S. rated.

Picture 2 is a DS series pressure transducer that we are wanting to put through I.S. testing and rating.

Picture 3 How we plan to use the two units together in hazardous locations.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Proportion-Air 2 An Intrinsically Safe Electro-Pneumatic Controller with a barrier Cubanski, Dave 0 0 0 0 0 0 1 0 0 0 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Intrinsically Safe Barrier for QB device
This capstone project challenges students to design, construct, and test an intrinsically safe barrier for our QB Intrinsically safe electro-pneumatic controller. This critical safety device will be used in industrial automation to prevent ignition in hazardous environments. The project will simulate real-world engineering constraints and safety standards, offering students hands-on experience in electrical design, safety compliance, and system integration.

Project Objectives
• Research and understand the principles of intrinsic safety and hazardous area classifications to determine if we meet their criteria (e.g., ATEX, IECEx, NEC, U.L., C.U.L, C.E.).
• Design an intrinsically safe barrier circuit that limits voltage and current to safe levels.
• Construct a working prototype using appropriate components (e.g., Zener diodes, resistors, fuses).
• Test the barrier’s performance under simulated fault conditions.
• Document the design process, testing methodology, and results in a formal engineering report.
________________________________________

Expected Deliverables
• A fully functional prototype of an intrinsically safe barrier to be used in conjunction with our QB Intrinsically safe unit.
• Electrical schematics and PCB layout
• Test plan and results demonstrating compliance with intrinsic safety principles
• Final report and presentation summarizing the project
________________________________________
Skills and Knowledge Areas
• Electrical circuit design and simulation
• Safety standards and compliance (IEC 60079-11, ATEX, etc.)
• PCB prototyping and soldering
• Instrumentation and data acquisition
• Technical documentation and communication
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU & Innsight Tech, Inc. Point-of-care biosensing of human tears for dry eye disease Pacey, Mark 1 0 3 3 0 0 2 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Innsight Tech is developing a reliable electrochemical platform technology to quantify tear fluid biomarkers and guide medical decisions. The value proposition is to strategically manage eye and systemic health conditions via non-invasive tear-fluid biomarkers. The company was co-founded in 2014 by Prof. Dipanjan Pan and Dr. Leanne Labriola (Ophthalmologist).

The company's first product is a multiplexed tear fluid biomaker test for dry eye disease.

Company website: https://www.innsightech.com/

The company's product on dry eye disease is OcuCheck, which simultaneously measures MMP-9 and tear film osmolarity on one test strip. With a sophisticated electrochemical sensor, the OcuCheck offers highly sensitive measurements and low limits of detection, surpassing competitors. The OcuCheck complements clinical exams for dry eye patients, enabling objective tracking of treatment response and disease progression. The platform work like an at home glucose monitor except no finger pricking is necessary. Familiarity with electrical/electrochemical sensing and Nyquist plot would be helpful.

The Learning Factory design team will work with Prof. Pan's lab at Penn State and Innsight Team to 1) take the electrochemical traces from the device and normalize it to the base sensor impedance; 2) apply signal processing to get the best realiable electrochemical features and automate the process; 3) develop an user friendly app to go with the measurements.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU & Luminous Global Tech At home self testing of breast abonormalities using Luminous Global Tech Runkle, Leeann 1 0 3 2 0 0 3 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)

Luminous Global Tech is developing world's first first breast familiarity tool designed to give users a visual reference of their breast health and embrace an awareness lifestyle. This technology illuminates soft tissue and blood flow in the breast, establishing a specific baseline for the user that they may identify changes or potential abnormalities. Areas characterized by visual darkness or shadows may indicate possible anomalies. Luminous is a non-invasive technique that enables the visualization of the venous flow/pattern in the breasts using a no risk Class 1 medical device. The device is available for use in Europe but not FDA approved yet.

The company is working with Prof. Pan's lab to achieve:

1) a ML/AI based algorithm to process the images collected with this sytem to identify abonormalities (microcalcification, pigmentation, vessel narrowing, etc.)
2) propose and test a better method to capture images
3) study use of a food grade dye as one time use applicator on the skin to increase the tissue transparency for better visibility.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Center for Immersive Learning and Digital Innovation 1 Development of Immersive Dementia Care Simulation Modules Using Mixed Reality Menold, Jess 3 0 2 3 0 0 0 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

This interdisciplinary project will support the development of an immersive simulation module for a standardized dementia care scenario using Mixed Reality (MR). This module will be used in a pilot study comparing the effectiveness of simulation modalities (VR vs MR) in preparing nursing, medical, and speech-language pathology students for clinical care of older adults with dementia and delirium. Deliverables will include: A working prototype of the MR simulation experience, An interface for user interaction and data collection (basic UI/UX), Documentation for module use and integration into a simulation curriculum, Optional: Use of AI-driven avatars or decision trees to simulate patient/family responses. The module will follow best practices in user-centered design, accessibility, and instructional technology. Collaboration with the College of Nursing’s Center for Immersive Learning and Digital Innovation will ensure that clinical accuracy and pedagogical value are met.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Center for Immersive Learning and Digital Innovation 2 Development of Immersive Dementia Care Simulation Modules Using Virtual Reality Ward, Robert 2 0 0 1 0 0 0 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)

This interdisciplinary project will support the development of an immersive simulation module for a standardized dementia care scenario using Virtual Reality (VR). This module will be used in a pilot study comparing the effectiveness of simulation modalities (VR vs MR) in preparing nursing, medical, and speech-language pathology students for clinical care of older adults with dementia and delirium. Deliverables will include: A working prototype of the VR simulation experience, An interface for user interaction and data collection (basic UI/UX), Documentation for module use and integration into a simulation curriculum, Optional: Use of AI-driven avatars or decision trees to simulate patient/family responses. The module will follow best practices in user-centered design, accessibility, and instructional technology. Collaboration with the College of Nursing’s Center for Immersive Learning and Digital Innovation will ensure that clinical accuracy and pedagogical value are met.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Center for Immersive Learning and Digital Innovation 3 Design and develop a robotic system capable of remotely accessing and administering intravenous medications and fluids Cubanski, Dave 1 0 3 0 0 0 2 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

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
PSU Center for Immersive Learning and Digital Innovation 4 Robotic Dressing Site Monitoring Device for Early Detection of Central Line Infections Pacey, Mark 1 0 3 0 0 0 3 0 0 0 0 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

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
PSU Center for Immersive Learning and Digital Innovation 5 Enhancing Patient Safety through Mixed-Reality Guided Central Line Insertions Runkle, Leeann 1 0 3 2 0 0 3 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Project Description: 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
PSU Center for Immersive Learning and Digital Innovation 6 VR Training for CLABSI Prevention During ICU Care Transitions Ward, Robert 2 0 0 1 0 0 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 involves designing and developing a virtual reality (VR) training module for ICU shift change handoffs with a focus on central line-associated bloodstream infection (CLABSI) prevention. The simulation will replicate an ICU environment and use interactive VR elements to engage learners in infection control protocols. Students will work with nursing faculty and clinical stakeholders to:

Design realistic user interfaces and interactions within a simulated ICU space
Program decision-making scenarios that require adherence to evidence-based CLABSI prevention steps
Integrate voice recognition or haptic feedback features to enhance realism
Develop performance analytics to track user compliance within the simulation
Test and evaluate the tool with interdisciplinary input from clinical partners
Deliverables will include: a functional VR prototype compatible with common headsets (e.g., Metaquest), accompanying user documentation, and a report on design decisions, evaluation metrics, and suggested iterations. The final product will be piloted in nursing education and clinical training environments.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU College of Medicine Newborn Fall Prevention With a Weight Sensor Choi, Kyusun 3 0 1 2 0 0 0 0 0 0 0 3 0

Non-Disclosure Agreement: YES

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Introduction: Breast milk and breastfeeding are the optimal choices for newborns, and most mothers are inherently motivated to breastfeed right after giving birth. It’s entirely natural for mothers, regardless of whether they’ve had a vaginal delivery or a cesarean section, to feel exhausted in the days following childbirth. This fatigue often leads to mothers unintentionally falling asleep during skin-to-skin care or breastfeeding sessions. Unfortunately, this can result in the baby slipping from their arms, risking severe and often life-threatening injuries. These incidents can occur even in hospital settings, despite the diligent monitoring by nurses. The Joint Commission reports 600-1600 such falls annually! Having a nurse around the clock is impractical, and relying on family members can be inconsistent due to their need to care for other children or responsibilities at home. Thus, a reliable monitoring device or sensor is essential that respects the mother's privacy while alerting her if she is at risk of falling asleep. This tool would prompt mothers to continue breastfeeding or safely place the infant in the bassinet for rest.


Why Current Strategies Fall Short! The presence of a 24/7 nurse or assistant in the mother’s room is not feasible and would infringe on the mother's privacy. Additionally, hospital staff often face competing responsibilities, making it impossible to dedicate a considerable amount of time to one mother. Even regular check-ins from nurses during the night cannot prevent falls; we’ve witnessed babies fall just 15 minutes after a nurse's last check. Family members may not be able to stay consistently, and maternal exhaustion does not magically disappear after leaving the hospital—it remains a persistent challenge. Sleep science suggests that it is invariable.


Relying on devices that monitor sleep patterns may provide alerts, but by the time a mother receives the notification, it may be too late; the infant may have already slipped.


Project Aim: The purpose of this project is to design and prototype a weight-sensor alarm system for a newborn baby bassinet.


Design:

Weight sensor- A compact sensor capable of detecting a weight of 1.8 kg should be installed beneath each bassinet mattress. This sensor will connect to a discreet speaker on the bassinet's rim, equipped with a silencing button. The sensor activates whenever the baby is removed from the bassinet, triggering an audible beep every five minutes. If the caregiver does not respond, the beep's intensity will increase every 20 seconds. Once the baby is returned, the alert will cease. This automation eliminates compliance issues, as the system operates independently of caregiver input.


Alternatively, when the infant is removed from the bassinet, an audible message is sent to the nurse's hospital phone, alerting her to check and monitor the baby until it is put back in the bassinet. This method can eliminate the nurse's frequent hourly monitoring, freeing her to focus on the aspects of care. This option also reduces maternal anxiety as silencing the alarm is not required frequently during feeding.


Initially, a nurse will activate the alarm upon placement of the bassinet in the mother’s room and deactivate it upon discharge. This proactive measure helps prevent dangerous fall incidents.


By Pradeep Alur, MD.

Neonatologist
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 Choi, Kyusun 0 0 1 2 0 0 0 0 0 0 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

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 Extension- Cameron County Cameron County Biomass Initiative Zajac, Brian 3 0 0 0 0 0 0 0 0 1 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

This project will focus on conceptual design and feasibility analysis for a biomass energy processing facility at a former lumber mill site in Emporium, PA. Students will develop facility configurations that optimize use of the existing square footage, identify renovation needs, and assess feasibility boundaries (i.e., what is possible within current infrastructure and what may require expansion or new construction). Open design elements include production layout, infrastructure planning, and operational workflows, allowing students to conceptualize multiple solutions and evaluate them based on performance, feasibility, and stakeholder input. Students will also explore integration opportunities with local businesses such as Emporium Hardwoods and regional auto parts manufacturers, identifying how biomass operations might complement or enhance existing industrial activity. Deliverables will include conceptual layouts, process recommendations, and assessments of potential biomass inputs and outputs, all informed by engineering analysis and community collaboration.

Cameron County is an economically distressed county in rural northcentral Pennsylvania. With the outsourcing of local industry over the past two decades, the county has experienced high unemployment rates, population loss, and a deteriorating social infrastructure. The retreat of economic opportunity is further exacerbated by the community fragmentation that often accompanies economic decline. As individuals find sustenance more difficult to achieve, resources normally allocated for community improvement are becoming less available. As community members see opportunities slip away, they find themselves in a position of ambiguity concerning their future. The ability to strategize long-term is, in many cases, replaced by desperate short-term reactive measures designed only to meet immediate needs. These short-term strategies often serve to remove or diminish future opportunities that might become available. In order to take control of their circumstances, key leaders in Cameron County are developing innovative strategies for sustainable economic development.

With extensive collaborative efforts already underway in Emporium (the Cameron County seat), local actors feel that a regional biomass energy processing facility, coupled with complimentary product development (e.g., biochar and steel production) well-suited to accompany primary production activities, would provide an opportunity to enhance economic development for entrepreneurs in northcentral Pennsylvania. A regional study sponsored by the Cameron County Commissioners, followed by site identification that is conducive to this sort of development (a former lumber mill), has encouraged those involved to proceed to the next step in project actualization. This effort intends to establish high-performance relationships between biomass activities with existing local manufacturers. Sintered metal parts manufacturing and lumber are the historic primary economic drivers for the community (over the past 50 years). By combining regional entrepreneurship education programs with the local skills, creativity, and knowledge, community members hope to encourage regionalized small business development. Penn State Extension and Cameron County Commissioners would like to engage Penn State Engineering faculty and students to conduct a project learning program to develop appropriate premises for this initiative. Combined with local efforts, the development will provide the means to clarify the necessary needs and systemic functions for project optimization.

The unique characteristics of the site in terms of opportunities and limitations present an adaptive canvas for participant improvisations. Communicating directly with local industry, property owners, and councilmen, students will design conceptual plant operations considering value-add product models suitable for the location. Considerations for design will include establishing high-performance relationships between biomass activities with regional manufacturers.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Football Flag Reaction Test Butler, Jared 3 0 2 3 0 0 3 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Summary: Design a field-ready reaction/agility training system for Penn State Football. You’ll design, build, validate, and deliver rugged wireless reaction training devices that present randomized visual cues and detect athlete responses (tap, proximity, or flag-pull), plus an app to run drills and log results. The focus is real-world use: fast setup, clear feedback for athletes and coaches, and durability. You’ll work with staff to shape drill presets, test the prototype, and deliver basic analytics (reaction time, accuracy, session summaries). Ideal for students interested in hardware, mobile apps, UX, and sports tech.

Outcome: A practice-ready system and pilot with the team.

Expectations: This project runs at a faster pace than most capstones and culminates in fully functional, user-ready devices that have undergone multiple rounds of user testing. The cadence will be demanding and technically rigorous; students who aren’t ready to hit the gas hard from Week 1 will find the pace overwhelming. If that challenge excites you, you’re our people.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU IME CFB Simulation Suite Ward, Robert 0 0 0 1 0 0 0 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)

Overview
The CFB Simulation Suite is an interactive platform designed to help our customers understand how financial volatility propagates through their supply chain networks. By simulating the Cash-Flow Bullwhip (CFB) effect and offering AI-driven advisory features, the tool shall enable the users to experiment with operational-financial trade-offs and develop data-informed strategies for managing risk.

Problem Statement
The project will address a critical gap for our customers. While our customers are skilled in supply chain optimization, their teams are often not adequately equipped to manage the direct financial consequences of operational decisions, a phenomenon known as the Cash-Flow Bullwhip (CFB) effect. This project is commissioned to develop an interactive, hands-on tool that allows users to analyze, simulate, visualize, and manage these complex dynamics directly, bridging the gap between operational theory and financial reality.

The project's required deliverables
• Phase 1: A functional backend system. While it will not have a graphical user interface, the tool must be immediately usable to perform static analyses of cash-flow volatility across real-world supply networks.
• Phase 2: An interactive UI that allows users to visualize a supply network, run simulations, and see the financial impact of their operational decisions in real-time.
• Phase 3: The fully functional CFB Simulation Suite, including all of the AI personas, which must be a tested and polished platform ready for seamless deployment to customers.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU International Health and Nutrition Equity Lab (Kodish) Malnutrition Detection in Resource Constrained Settings Pacey, Mark 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: YES

Images and Additional Links (if provided)

Approximately 20 million children under 5 years of age – mostly in low-and-middle-income countries – suffer from severe acute malnutrition (SAM) annually, an estimate which reflects the same number of people living in all of New York state. SAM cases are serious, requiring timely medical intervention, without which recovery is difficult. Among those children who do have access to timely care, case-fatality rates still range between 20 – 60% depending whether complications, such as edema, co-exist. While the W.H.O. has established protocols for treating SAM cases, a primary challenge lies in accurate and timely identification of SAM cases for referral to health centers for treatment. Generally, trained community health workers with literacy can screen for SAM using a mid-upper-arm-circumference (MUAC) measurement; however, many health workers across contexts find MUAC challenging due to various constraints. Further, emerging evidence suggests that SAM screening should be done at home by caregivers, not only by facility-based health workers, given the importance for acutely malnourished children to receive timely care. MUAC measurement is much more challenging for caregivers in LMIC settings, thus underscoring the need for a cost-effective SAM screening tool that can be used effectively in LMICs among health workers and caregivers, alike.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Mechanical Engineering ASME e-Human-Powered Vehicle Neal, Gary 3 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: YES

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
PSU Nittany Motorsports 1 Suspension Component Redesign and Manufacture Neal, Gary 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: YES

Images and Additional Links (if provided)

This project involves the redesign of an existing Formula SAE suspension component to be manufactured using metal casting techniques. Students will adapt the geometry of the existing components for castability, produce prototype components, and conduct both destructive and non-destructive testing to evaluate and prove performance and structural integrity.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Nittany Motorsports 2 Nittany Motorsports Competition Cart Neal, Gary 0 0 0 0 0 0 0 0 3 2 3 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Nittany Motorsports requires a rugged and mobile storage solution to streamline logistics during competitions and track days. This project involves the design, prototyping, and testing of a custom-built toolbox/transport cart capable of carrying essential equipment for our racing team.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
PSU Speech, Language and Hearing Clinic Designing for Access: A Team-Based Approach to Supporting Children with Neurodegenerative Disorders Through Interdisciplinary Education Menold, Jess 0 0 0 2 0 0 0 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

This interdisciplinary project brings together student engineers and graduate student speech-language pathologists (SLPs) at Penn State to support environmental access and communication for a child with metachromatic leukodystrophy (MLD)—a progressive neurodegenerative disorder that affects motor control and speech. The child is unable to access a computer or augmentative and alternative communication (AAC) system through direct selection.

The project is designed to address the child’s current needs and prepare for anticipated changes associated with the progression of MLD. The goal is to support the child’s communication and participation at home and at school through personalized, accessible technology solutions. There are two primary areas of focus:

1. Adapted Cursor Development
Engineers will develop a cursor system that wraps around the child’s display, providing a simplified, accessible interface for interacting with his computer. The goal is to identify reliable selection/alternative access methods (adapted joysticks) for his current needs (across vision, motor, cognition, and language) that are adaptable for future changes.

2. Environmental Control Solutions
The team will also design low-effort, flexible tools to help the child engage with his surroundings independently. This includes systems to support access to books, toys (remote control cars), music, and video, as well as environmental controls for lights, thermostats, and other smart home devices. Solutions will prioritize ease of use, adaptability, and long-term use.

This project highlights the value of collaborative, person-centered design and interprofessional teaming and learning, with engineers and SLPs working closely to assess needs, prototype solutions, and iterate based on real-world use. The ultimate goal is to improve communication and participation across environments now and in the future.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Quaker Houghton Tool Coating Performance in Drilling of Steel Alloys Zajac, Brian 0 0 0 0 0 0 0 0 0 1 3 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Background
A variety of tool coatings are widely used for machining operations in the automotive industry. Tool coatings can help improve machining performance by extending tool life and increasing efficiency during machining. Depending on the type of coating, thermal resistance and increased lubricity can also be observed. Our group wants to explore the effects of tool coatings in machining of two steel alloys, at two speeds, to provide data we can refer to when selecting coated tools for future projects. In industry, tool wear is a major factor in determining how long a tool can be used for a machining operation. For this project, tool wear will be the main method of observing how well the different coatings perform and if they show a positive or negative effect compared to the control drill. To test the different coated carbide tools, the team is asked to drill two different steel alloys at two different speeds with a variety of carbide coated drills and a control tool to a specified number of holes. The test is based on how many holes were drilled with the control tool until it reaches 0.3 mm of maximum flank wear length which is the failure metric. Tool wear should be recorded at intervals holes until completion. After all tools have been tested the team can look at the tool wear measured and continue to drill with the carbide coated tools that showed the least amount of wear to determine how many holes can be drilled until failure of 0.3 mm flank wear length is reached.

Deliverables:
1. The team researches the different types of coatings used on carbide drills and their purposes in industry.
2. The capstone team researches what is considered tool wear failure in the automotive industry.
3. Design an experiment focusing on using:
a. 4-5 different coated carbide drills
b. Control carbide tool
c. Machine two steel alloys at two different speeds to a specified number of holes based using one Quaker Houghton metalworking fluid.
d. Flank wear of each tool will be measured at certain intervals until the specified number of holes is met. The tools that do not reach failure after all initial testing is completed can be used to drill more holes until the flank wear reaches the failure metric.
4. Create a 3-D printed holder for the tools so that the tool is oriented correctly every time it is measured to ensure flank wear is measured accurately.
5. Report findings at end of semester and give presentation to Quaker Houghton team.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Real-time Science Laboratory - Pennsylvania State University AI Goggles to Understand Influences on Well-being with Life-changing Injury or Pathology Menold, Jess 0 0 3 2 0 0 0 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Neurobehavioral disorders, such as spinal cord injury, addiction, and stroke, are life-changing. Patients with these injuries and disorders are faced with intense and lasting changes to almost every aspect of their lives, including physical limitations, changes to living situations, social stigma, upheavals of social, family, and romantic relationships, and often the onset of other psychological issues like depression and anxiety. Ordinary day-to-day influences, ranging from basic social interactions to care-team decisionmaking processes, can have large effects on the overall progress and patient well-being. Understanding these influences requires intensive data collection and advanced analysis techniques, which can add immense cost and burden to patients.

This project will develop open hardware and software specifications and a set of prototypes for a body-mounted data collection system capable of collecting and transmitting audiovisual data to a server for privacy-preserving AI-based processing in real time. Current prototypes use a glasses-like form factor, although others may be possible.

This project is part of a larger project to develop individualized interventions to improve well-being in patients recovering from long-term disorders and life-changing injuries.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Rogers EZ Shower LLC Rolling tub tray for individuals with breathing difficulties Menold, Jess 2 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: YES

Images and Additional Links (if provided)

Key Features:
- Rolling Capability: The tray is equipped with wheels, enabling smooth movement
towards or away from the user, providing flexibility and convenience during showering.
- Accessibility: By eliminating the need for bending down and providing easy access to
essential showering tools and products, the invention promotes independence and
comfort for individuals with breathing difficulties.
- Adjustable Shower Control: The handheld shower anchor empowers people to customize
their shower experience according to their preferences and needs.
- Enhanced Safety: The design prioritizes safety by reducing the risk of slips or falls
associated with reaching or bending down in the shower, particularly for individuals with
compromised respiratory function.
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 – Phase II Development Wang, CY 0 0 3 2 0 0 0 0 0 3 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Background:
In Spring 2025, a CAPstone team at Penn State successfully developed a functional prototype of an Automated Tool Imaging Station. The system was designed to capture high-resolution images of cutting tools at predefined positions to monitor wear behavior. The prototype demonstrated key capabilities such as automated positioning, adjustable lighting, and compatibility with tools mounted in holders. The project laid a strong foundation for a scalable imaging solution.

Project Scope – Phase II:
This follow-up project aims to build upon the initial prototype by addressing limitations identified during testing and expanding the system’s capabilities. The focus will be on improving precision, usability, and adaptability to different tool geometries and imaging requirements.

Objectives:
Review the Previous Solution: Analyze the existing prototype, including its motion system and overall architecture, to identify strengths, weaknesses, and opportunities for improvement.
Enhance Imaging Precision: Improve the repeatability and accuracy of image capture, particularly for cylindrical side views.
Refine Lighting System: Optimize the lighting configuration to ensure consistent image quality across various tool materials and surface finishes.
Improve System Flexibility: Make the system more easily configurable for a wider range of tool sizes and imaging positions.
Develop a User Interface: Create or enhance a user-friendly interface for setup, operation, and image review.
Increase System Robustness: Strengthen mechanical and software components for reliable operation in workshop environments.

Deliverables:
A refined and enhanced prototype of the imaging system.
Technical documentation of all improvements and system architecture.
A user manual for system configuration and operation.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
ShareMyBook ShareMyBook Ward, Robert 0 0 0 1 0 0 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)

• A working ShareMyBook prototype that responds to mobile devices.
• A user flow with features for adding, requesting, swapping, and hosting clubs.
• Integration with a simple chat/messaging interface.
• A report and demonstration video that provides an overview of the next-phase roadmap, technical integration, and usability testing.
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: YES

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 fuel-efficient vehicle that meets all the competition rules and then compete against nearly 100 other North and South American schools. 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. Yes, we actually drive our car on the Indianapolis Motor Speedway track! 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 other things.
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 0 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

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 fuel-efficient vehicle that meets all the competition rules and then compete against nearly 100 other North and South American schools. 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. Yes, we actually drive our car on the Indianapolis Motor Speedway track! 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 other things.
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 0 0 0 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

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 fuel-efficient vehicle that meets all the competition rules and then compete against nearly 100 other North and South American schools. 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. Yes, we actually drive our car on the Indianapolis Motor Speedway track! 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 other things.
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
SME Solutions Inc Edge-Optimized Image Upscaling Choi, Kyusun 0 0 1 2 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

The senior design team will develop a working prototype that captures low-resolution video from a camera, compresses it in real time using the high-performance libjpeg-turbo codec, and transmits it to a second embedded system over a constrained communication link. On the receiving end, the system will decode the JPEG stream and pass the images through a lightweight AI-based super-resolution module to upscale the video for display. This will demonstrate an effective reduction in transmission bandwidth while preserving important visual details for end-user consumption.
The solution will be optimized for edge-class hardware, where processing resources are limited. The team will evaluate and implement a multi-processor offloading strategy, leveraging CPU, GPU, or hardware accelerators, to sustain real-time performance of at least 30 frames per second. The final deliverables will include bandwidth and quality benchmarks (e.g., bitrate savings, PSNR/SSIM scores, and latency measurements), as well as deployment scripts and documentation for replicating the pipeline on typical ARM-based platforms.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Spectrum Control Inc Industrial air compressor operational efficiency Wang, CY 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: YES

Images and Additional Links (if provided)

Spectrum Control has led the way in developing reliable, high-performance technologies for powering and conditioning RF and microwave signals and protecting electronic equipment from electromagnetic interference. We continue to push out the limits of the possible today, innovating in material science, design engineering, and manufacturing technologies. Spectrum Control is the world’s leading expert in signal protection, conditioning, and processing that enables modern defense and aerospace systems. Our customers use our components, modules, subsystems, and custom solutions to protect warfighters and their equipment and enable mission-critical surveillance, communications, and threat mitigation.

A valuable study we would like to see conducted on a 200-horsepower industrial air compressor would comprehensively evaluate its operational efficiency, optimal placement within our facility, capacity configurations, cost analysis, and system integrity. This study should begin with a thorough mapping of the existing compressed air system, leak detection, and flow metering to quantify line losses and assess their impact on energy consumption.

Additionally, the study should assess multiple installation points within the plant to determine the most effective physical location for the compressor. This includes analyzing ambient temperature, humidity, ventilation, and proximity to points of use, as well as evaluating pressure drop caused by distance and piping configuration. Capacity options, such as adding additional compressors or comparing fixed-speed versus variable-speed drive (VSD) compressors, should also be evaluated based on the plant’s actual air demand profile, which can be gathered through data logging over a representative period. Effective use of mixing technology, since a large portion of compressed air is used for mixing. Cost and efficiency analysis should consider not only the initial capital investment and installation costs but also long-term energy consumption, maintenance requirements, and lifecycle operating costs. The goal of this study is to recommend the most cost-effective, energy-efficient, and reliable setup for operating a 200-hp air compressor in our industrial environment.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
TailGater TailGaiter Zajac, Brian 0 0 0 0 0 0 0 0 0 1 3 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Do you have a vehicle with a backup camera? How often do you find yourself giving it a swipe with your hand, or just wishing you had when you shift into reverse to park? A novel proof-of-concept has been developed that uses a passive, mechanical design and the natural movement of the vehicle to clean backup cameras while avoiding obstruction. In this capstone project, your goal will be to refine this existing concept and bring the product to market. Design updates are needed to improve cleaning performance, vehicle compatibility, appearance, marketability, and manufacturability. At the end of the project, you are strongly encouraged to take advantage of PSU resources much as the Happy Valley LaunchBox to patent the idea and create a start-up company to commercialize the design. This project will be a collaboration with the Smeal College of Business, and engineering students with a strong entrepreneurial mindset are encouraged to apply. All intellectual property developed throughout the project will be owned by the student team. A portion of potential royalties will be used to benefit future PSU students, with the rest split among the student inventors. With a student designed and developed solution, coupled with built in consumers at campus activities, you could provide a Penn State proud solution and launch your own business!
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
TE Connectivity AI for Tubing Outer Diameter Wavy Condition Detection Choi, Kyusun 0 0 1 2 0 0 0 0 0 0 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Overview: The TE AI Cup is a global competition where TE Connectivity partners with university teams to tackle real-world industrial AI challenges in manufacturing environments. Students selecting this project are expected to meet regularly during the Spring semester (approximately bi-weekly) and virtually participate in the AI Cup Final Competition in May, presenting their solutions alongside teams from around the world. Winning teams may receive scholarship of up to $6,500, along with internship or full-time opportunities at TE Connectivity.

This project focuses on developing an AI algorithm to predict "wavy condition" in tubing product. A wavy condition occurs during the tubing expansion process, where instability in the outer diameter (OD) causes chatter marks on the surface. These defects can compromise the product's functionality and performance. To monitor this proble, a laser-based measurement system is used to capture real-time OD data from 4 angular positions around the tube.

Goal: Design and implement a real-time AI algorithm that can predict the onset of wavy conditions by analyzing OD data from the previous few seconds. The algorithm should be validated across multiple scenarios to ensure robustness and reliability.

Deliverables:
- A functioning AI model capable of predicting wavy conditions in real-time.
- Demonstrated performance of the model using test datasets or real-time input.
- A final 10-minute presentation summarizing the findings, methodology, and results, prepared for the AI Cup competition
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Aluminum Association, Inc. Aluminum Extrusion Tolerance Calculator - Phase III Ward, Robert 0 0 0 1 0 0 0 0 0 2 0 3 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

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 semi-finished intermediate products).
One of our widely used “compendium” publications is Aluminum Standards & Data (AS&D), a derivative of the ANSI H35 standards series that contains multiple chapters’ worth of tolerancing data for semi-fabricated aluminum products among other things. AS&D is published in print and electronic formats with a dedicated version each employing U.S. customary units and metric units. 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 ultimate goal of this project is to continue the development of (or develop from scratch) an online calculator that can help users accurately determine what tolerances apply to the aluminum products they fabricate or purchase from a fabricator. As a starting point for this module of the project, we will deal with tolerances that apply to extruded wire, rod, bar and profiles fabricated using aluminum alloy-tempers, as illustrated by a series of tables in AS&D Chapter 11. Tolerances that apply may include dimensions (e.g., wall thickness, radius, etc.), 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. However, adding further complexity are multiple footnotes and conditions which 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 and Spring 2025, the Aluminum Tolerance Calculator teams (Phase I and II) at PSU’s Learning Factory worked on developing prototypes for table 11.2 that could accept geometric property and dimensional inputs of the cross-section of a part from the user and calculate tolerances that apply for that part, taking into account all the complexities of table 11.2 including its footnotes. These interim deliverables are currently stored on GitHub. The phase III team (Fall 2025) will inherit these deliverables and will be assigned the project of creating a complete and functioning web-based calculator program for AS&D Chapter 11 Table 11.2. If development goes well beyond expectations, a stretch goal would be to also incorporate Chapter 12 tables 12.2 and 12.20 into the calculator (similar in concept, but dealing specifically with diameters of pipes and tubes made by extrusion and drawing respectively) The Phase III team is encouraged to employ their creativity to refine and enhance the model developed by the prior team and/or to take it forward entirely 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 expected outcome of this project is to create a helpful calculator resource that could be packaged with the publication itself or made available separately on our website. A more advanced challenge to augment to the project, purely optional, would be to develop a program that can analyze an imported 2D computer aided drawing of an extruded cross-section and subsequently recognize and recommend what tolerances apply for each of the geometric features of the cross-section based on table 11.2. 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 table values to keep up with revisions to the publications and easily expandable to include other tables and other product forms from AS&D.

Project Deliverables:
A fully functional, web-hosted calculator program that can be used in conjunction with the tables in AS&D chapter 11 table 11.2 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 tables and chapters in the future.
Stretch goal 1: Expand the scope of the calculator to include tables 12.2 and 12.20.
Stretch goal 2: Functionality to import 2D cross-sectional drawings of extrusions and recognize tolerances that apply.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
The Hungry Group Digital twin of an automated food assembly robot Zajac, Brian 0 0 0 2 0 0 0 0 0 1 0 0 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: NO

Images and Additional Links (if provided)

The Hungry Group operates a next-generation, fully automated kitchen powered by a food-assembly robot. We serve customers across multiple brands every day and are committed to delivering meals within strict timing windows to maximize satisfaction and throughput.

As part of this capstone project, you will join our product-engineering team to create a simulation-based digital twin of the existing assembly line and use it for system optimization and what-if analysis to drive meaningful performance gains. Your work will unfold in four progressive phases:

1. Digital-Twin Development: Build and validate a high-fidelity, system-level model of the current assembly robot, capturing mechanical-motion timing, state-machine control logic, and upstream/downstream interactions.
2. Baseline Performance Characterization: Run “day-in-the-life” order streams through the twin to quantify current cycle times, queue lengths, and resource utilization relative to our timing goals, establishing the benchmark against which all future improvements will be measured.
3. Capacity-Limit Analysis: Stress-test the model with escalating demand scenarios to pinpoint the maximum order volume that still meets the timing service level requirements, providing clear guidance how much headroom (or shortfall) exists before service levels degrade.
4. Bottleneck Identification and Design Iterations: Use simulation to locate rate-limiting steps and trial improvements such as parallelizing tasks, increasing dispenser speeds, or adding or removing dispensers, and then prioritize the upgrades that deliver the greatest gains in productivity while maintaining service timing requirements.

Achieving these objectives will unlock higher hourly throughput, increase reliability, reduce wait times, and open new revenue opportunities.
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 High-Temperature Actuator Shaft Design for Supersonic Aircraft Wang, CY 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: YES

Images and Additional Links (if provided)

CONTEXT:
Control surfaces (e.g. actuated fins) of supersonic flight vehicles experience large mechanical and thermal loads from extreme aerodynamic environments. These loads are transmitted through the actuator shaft, which must be strong enough to bear mechanical load and prevent large thermal loads from reaching sensitive servomechanisms used to power control surfaces. As flight vehicles fly faster and pull increasingly aggressive maneuvers, there is an increasing need for designs to be high strength, attenuate stressing thermal load, and be minimize weight.

CHALLENGE CONTEXT:
Design, analyze, and test a next-generation control surface actuator shaft to achieve strength and thermal resistance to a defined loading scenario that minimizes structural weight.

TECHNICAL APPROACH:
- Explore methods to reduce weight such as topologically optimized structures under prescribed loading
- Explore novel materials and/or design morphologies that enable high strength, high thermal resistance, and reduced weight at high temperatures
- Utilize state-of-the-art manufacturing methods, such as additive manufacturing to produce a prototype actuator shaft
- Develop and execute mechanical and thermal tests to validate the performance of a prototype actual shaft


DELIVERABLES:
- Conceptual design and prototype of a high strength, thermally resistant, and lightweight control surface actuator shaft
- Data products from lab-scale mechanical and thermal testing of the prototype shaft
- Thermal-mechanical analysis of the final design with comparisons between strength, thermal resistance, and mass relative to an APL-provided baseline component
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Tinius Olsen Testing Machine Company Automated material Testing System: Integrating sensors and AI to automatically detect specimen characteristics Kimel, Allen 0 0 0 3 0 0 0 0 0 0 1 2 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Are you ready to use cutting-edge technology to solve a real-world engineering challenge? We're looking for passionate students to join us in building a working prototype of a smart system that will revolutionize the field of material testing.

Imagine a Universal Testing Machine (UTM) that can automatically identify a specimen just by looking at it. Currently, operators must manually input details for every single test—a process that is time-consuming, repetitive, and prone to human error. Our project aims to solve this by creating an automated system that is more consistent and efficient than a human operator, saving valuable time and improving data quality across the board.

The goal is to develop a working prototype of an automated sensor and AI system capable of identifying and characterizing material specimens for a Universal Testing Machine. The UTM operator simply holds a specimen up to the sensor and it detects the following characteristics of the specimen:
• The type of specimen; test coupon, rebar, rope, lap joint, etc.
• The material; metal, plastic, rubber, composite, etc.
• The shape of the specimen; round, flat, dog-bone, etc.
• The dimensions of the specimen; width, thickness, length, length of gauge section, etc.

During the project, you will:
• Design and build a multi-sensor prototype that can be integrated into a UTM to analyze test specimens. The prototype will integrate different sensor technologies (e.g. cameras, inductive sensors, load cells) to gather comprehensive data on specimen properties. You will develop and train a machine learning model to accurately infer a specimen’s characteristics (type, material, shape, and dimensions) from the combined sensor data.
• Rigorously test the prototype to demonstrate its ability to identify and characterize specimens with higher accuracy and consistency than manual methods.
• Prepare and deliver a comprehensive final report, a working prototype demonstration, and a presentation of our findings.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
TMP Manufacturing Company, Inc. 1 Redesign of Manufacturing Work Platform Wang, CY 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: YES

Images and Additional Links (if provided)

Tafco manufactures custom walk-in coolers, freezers, and insulated panels used in industries like pharmaceuticals, military, and food service. Our foam-in-place urethane panels offer excellent thermal performance but are challenging to produce due to the size and complexity of the molds.

During production, workers spray foam into large molds positioned several feet off the ground. A previous capstone team built a platform to help workers reach the mold opening, but the current design has limitations. It’s too short, lacks flexibility, and doesn’t fully support safe access across the mold surface.

This project involves redesigning the platform to improve ergonomics and safety. Key goals include: 1) increasing platform height; 2) adding a side-to-side adjustable ladder for mold access; and 3) designing a stowable ladder system to keep the platform clear when not in use.

Deliverables include engineering analysis, CAD models, and a functional prototype to be tested on-site.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
TMP Manufacturing Company, Inc. 2 Redesign of Sheet Metal Tilting Table Zajac, Brian 0 0 0 0 0 0 0 0 0 1 0 2 0

Non-Disclosure Agreement: NO

Intellectual Property: NO

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Tafco manufactures custom walk-in coolers, freezers, and insulated panels used in industries like pharmaceuticals, military, and food service. Our foam-in-place urethane panels are built using cut sheet metal, which is formed and assembled in-house.

In the panel production process, large rolls of sheet metal are cut into flat sheets on horizontal tables. After cutting, each sheet must be tilted approximately 45 degrees to load onto a panel carrier for transport through the manufacturing line. A previous capstone team built a tilting table to assist with this step, but the current design has limitations. It does not accommodate workers of different sizes and strengths. For some, the table is too heavy to operate and for others it is too light and unstable.

This project involves redesigning the tilting table to improve ergonomics and safety. Key goals include: 1) making the tilt mechanism easier and safer to operate; 2) adding an adjustable counterweight or damper system; and 3) ensuring quick and consistent adjustment between shifts and users.

Deliverables include engineering analysis, CAD models, and a functional prototype to be tested on-site.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Wabtec 1 Advanced Copper Joining Methods Wang, CY 0 0 0 0 0 0 0 0 3 2 3 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Conduct a tradeoff study on Copper to Copper fusing techniques with a focus on optimizing for highest fatigue strength and highest electrical conductivity through the joint. Use an AC Motor “Rotor Bar to End Ring” design case as the baseline for this study.

Evaluate traditional and non-traditional copper to copper joining methodologies (brazing, crimping, laser welding, electron beam welding, friction stir welding, etc).
Within each potential methodology, determine the “best in class” process to optimize fatigue and electrical conductivity (example: brazing requires a braze alloy selection, flux selection and heat applicator… which is best)?

Compare the best in class options within each methodology up to a top-level comparison between methodologies that will then define the “best in class” joining method.

Define a Validation Plan that will prove out conclusions from the trade-off study.

Stretch Goal: Identify vendors that can provide samples for each joining method. Provide a budgetary quote for sample parts from each vendor.

Stretch Goal: Identify laboratory resource to conduct the validation plan. Provide a budgetary quote to complete the full scope of lab work.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Wabtec 2 Composite Impeller Prototype Development Rattner, Alex 0 0 0 0 0 0 0 0 3 0 2 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

A physical prototype(s) of the non-metal fan is needed to trial manufacturing feasibility of the design concept. Final product of this project is ultimately at least one prototype part that can be used for non-metal fan demonstration testing.

Project may leverage and/or modify the existing 2025 PSU Capstone team design work as needed.

Thorough considerations for SAFETY with use of the prototype part is CRITICAL. Finished fan is expected to be capable of safe operation up to maximum speed (4,000 RPM). It is expected the prototype part will be capable of running from 0 to max RPM thousands of times over the course of demonstration testing.

DFMEA for prototype part along with validation activities intended for the initial phase of prototype use.

Prototype part construction must consider all application needs – max operating speed, airflow performance, etc.

Prototype should be properly balanced before installation on a blower. Wabtec resources may be used to conduct the balancing step.

Stretch Goal: Prototype to be assembled successfully on existing blower assembly (shaft/contravene).

Stretch Goal: Complete a core demonstration test on the part to validate successful development of the proof of concept.

Stretch Goal: Production manufacturing source identification along with budgetary quotations for tooling and piece part prices.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Wabtec 3 Optimization of Multi-Axle Vehicle Drive Systems Using AI Ward, Robert 0 0 3 1 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 locomotives are deployed across a wide range of operational scenarios, from single-unit configurations to multi-locomotive consists supporting long and heavily loaded trains. These systems operate under diverse conditions, including varying terrain, trip durations, speeds, grades, curves, and environmental factors.

Currently, train operators manually adjust locomotive power in response to changing conditions. While effective, this manual control introduces inefficiencies due to human error and suboptimal coordination of locomotive resources. Additionally, the system's performance is influenced by complex interactions among mechanical and electrical subsystems—such as traction and vehicle controls, rectifiers, inverters, engines, alternators, switches, and gear assemblies.

Each locomotive is equipped with multiple traction motors (typically 4, 6, or 8), each responsible for driving an axle through a gear mesh, thus rotating 2 axle mounted wheels and propelling the locomotive. Coordinated control of these axles is essential for achieving optimal propulsion and overall system efficiency.

The Penn State Capstone team will be provided with representative duty cycles and system loss data. The goal is to develop AI-driven solutions that can intelligently manage and optimize drive system performance in real time. These solutions should be designed for potential integration into onboard control systems, though partial offboard implementation is acceptable if necessary.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Wabtec 4 Gearcase Passive Filtration Wang, CY 0 0 0 0 0 0 0 0 3 2 3 1 0

Non-Disclosure Agreement: YES

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

Develop robust solution which removes debris from oil and quarantine it away from bearing and gears. Quarantined area to be cleaned when gearcase is opened for overhaul maintenance, approximately every 1-2 years.

Review Wabtec Gearcase ASM drawings including gearcase top, gearcase bottom, gears, and related components to determine available space for the new assembly

Recommend validation activities for design demonstration

Analysis must consider all application needs – Duty Cycle, Low & High Speed, Shock, Thermal, multiple angular positions of TM

Recommend maintenance cycle, target maintenance interval is > 2 years

Preliminary requirements of gearbox filtration system:
– Contained within existing gearcase
– Any filters must not require maintenance prior to overhaul
– No motors or other powered devices
– Quarantines debris away from bearing and gear mesh
– Allows oil to adequately flow within the gearcase to lubricate bearing & gears

Stretch Goal – Guide oil directly into bearing at 12 o’clock or 6 o’clock positions
Stretch Goal – CFD analysis of oil flow to gears & bearing
Stretch Goal – Consider options to extend oil life & overhaul period to more than 2 years
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Walmart Inc. Fan-tastic Project: Engineering for Performance, Power, and Peace & Quiet Wang, CY 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: YES

Images and Additional Links (if provided)

This capstone project focuses on the design and development of consumer fans that achieves optimal performance across three key metrics: maximum airflow, minimal power consumption, and low noise levels.

The project will involve evaluating existing fans designs, identifying best-in-class design features, and applying engineering principles to prototype improved fan concepts.

Key activities will include:
-Benchmarking of current fan designs
-Measurement of airflow (CFM), air speed, power draw and noise
-Create innovative blade designs or concepts (e.g. biomimetic blade design etc.) that maximize airflow with minimal energy
-Use CAD and CFD tools to simulate airflow and acoustic performance of different blade designs and configurations
-Apply findings to development and creation of fan prototype(s)
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Westinghouse Electric Company 1 Automated Induction Coil Winding Device Mittan, Paul 0 0 3 3 0 0 2 0 3 3 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

As part of the research and development efforts of the eVinci® Microreactor various inductance-based sensors are being constructed and tested. During the development of these sensors, a rapid prototyping methodology is employed. To accommodate this testing methodology, the sensors are assembled manually. This process can be improved by creating an automated inductance coil winding machine.
The goal of this design team will be to create an automated inductance coil winding machine. The machine shall be able to accommodate a wide range of geometries and measure the number of turns and pitch of the coil windings it produces.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Westinghouse Electric Company 2 Scanning Electron Microscope (SEM) Noise Isolation Design Rattner, Alex 0 0 0 0 0 0 0 0 2 0 0 1 0

Non-Disclosure Agreement: NO

Intellectual Property: YES

Physical Prototype or On-Campus Equipment: YES

Images and Additional Links (if provided)

A scanning Electron Microscope (SEM) is a sensitive surface topography measurement device capable of achieving one (1) nanometer resolutions. As part of the development of the eVinci® Microreactor, Westinghouse has purchased an SEM. The SEM is situated in the Etna material science testing center. In the SEM’s current position some environmental influences may be experienced by changes to the surrounding environment. For instance, a forklift being driven by, or a furnace rejecting heat to the room. While logistical planning can eliminate the influences of surrounding effects, it is desirable to enable operation of the SEM during all hours.
The goal of this design team will be to design a noise and temperature isolation system to minimize the influence of surrounding environmental effects on SEM measurements. The solution shall enable precise measurement regardless of normal surrounding ambient lab conditions.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
Worley Group Inc. Assessment of Thermal Performance of the New CHP Unit at Penn State West Campus. Wang, CY 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)

A new 7MW Combined Heat and Power (CHP) unit was built at the Penn State West Campus in 2021. The team will collect historical operating data of the CHP unit and evaluate the performance of Gas turbine and Heat Recovery Steam Generator (HRSG). The objective is to compare the current operation with the original design to identify any performance shortfall and/or degradation through the three years operation. The engineers from Worley will provide the necessary guidance to the students to conduct the assessment. The final deliverables will be a presentation and a report.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
WSSC Water 1 Smart IoT Valve Tracker - Team 1 (valve database and GIS integration) Ward, Robert 0 0 2 1 0 0 0 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)

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 a massive network of underground pipes and valves. The total number of valves in our network is roughly 55,000!

Proper pressure and flow balance of the network is depended on valves being operated correctly. To ensure all valve are operated correctly WSSC Water needs a quick turn-around solution that involves the development of a Valve Operation UI within four months. This smart UI is intended to reduce human error, provide alerts for mispositioned valves, and automatically integrate valve position data with GIS. The application will enhance accuracy, accountability, and safety by automating data entry, reducing manual error, and enabling alerts that can help minimize customer impacts. This tool will be deployed to the phone of every company employee who operates valves and to all relevant managers.

The Smart IoT valve database and phone-based UI project involves developing a mobile application to improve valve tracking, reduce human error, and automatically integrate valve status data with GIS. The scope to be complete in one semester includes the smart database/UI development and field deployment. The smart UI will record valve positions by Asset ID, replace manual forms with a digital database, send reminders to return valves to proper positions, and issue alerts for critical customers such as hospitals and schools. The deployment portion will also include a site visit and staff training.

Initial plans are for Team 1 to focus on valve data and GIS integration. Team 2 will focus on the app and UI development.

The project will allow WSSC Water to continue to provide a highly reliable water source to approximately 2 million customers by allowing WSSC Water to reliably “Deliver the Essential”.
Company Name Project Title Faculty Contact BME CHE CMPEN CMPSC DS ED EE EGEE ESC IE MATSE ME NUCE
WSSC Water 2 Smart IoT Valve Tracker - Team 2 (app UI development) Ward, Robert 0 0 0 1 0 0 0 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)

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 a massive network of underground pipes and valves. The total number of valves in our network is roughly 55,000!

Proper pressure and flow balance of the network is depended on valves being operated correctly. To ensure all valve are operated correctly WSSC Water needs a quick turn-around solution that involves the development of a Valve Operation UI within four months. This smart UI is intended to reduce human error, provide alerts for mispositioned valves, and automatically integrate valve position data with GIS. The application will enhance accuracy, accountability, and safety by automating data entry, reducing manual error, and enabling alerts that can help minimize customer impacts. This tool will be deployed to the phone of every company employee who operates valves and to all relevant managers.

The Smart IoT valve database and phone-based UI project involves developing a mobile application to improve valve tracking, reduce human error, and automatically integrate valve status data with GIS. The scope to be complete in one semester includes the smart database/UI development and field deployment. The smart UI will record valve positions by Asset ID, replace manual forms with a digital database, send reminders to return valves to proper positions, and issue alerts for critical customers such as hospitals and schools. The deployment portion will also include a site visit and staff training.

Initial plans are for Team 1 to focus on valve data and GIS integration. Team 2 will focus on the app and UI development.

The project will allow WSSC Water to continue to provide a highly reliable water source to approximately 2 million customers by allowing WSSC Water to reliably “Deliver the Essential”.
 
 

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