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Welcome to the 2014 Senior Design Clinic! What you see here today are 21 working prototypes which 8 months ago were nothing more than ideas. 17 companies and non-profits have engaged our students with the real life experience of asking, “is it possible?” then letting the teams go to work. The teams will all tell you that at times it got tough and they themselves weren’t sure how it was all going to unfold. And that is exactly what we are trying to capture in the St. Thomas Senior Design Clinic. Where the comforts of well-defined textbook problems are abandoned, real engineering emerges. What you see here today is the manifestation of that uncertain process of translating ideas into reality.

In short, what you see here today is engineering.

On behalf of the School of Engineering faculty, I would like to thank you for coming today. We are grateful for the support of the sponsoring companies and non-profits who have committed the funds, equipment, and time to truly make this a great experience for our students. And lastly, we are especially grateful for the support of the family and friends that each one of our seniors has relied upon to make it this far in their incredible life journey.

Again, thank you and enjoy!

Don Weinkauf - Dean of Engineering

2014 Senior Design Clinic

@ Engineering St. Thomas

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To find out more about how your company can get involved with the Senior Design Clinic at St. Thomas, just call our main office.

(651) 962-5750

or email: dhweinkauf@stthomas.edu

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Table of Contents

Magnetic Vascular Grafts – Mayo Clinic ......................................................................... 1

Light-Cured Conformable Polymer Stents – Mayo Clinic ............................................... 2

Work Suit Cooling – 3M .................................................................................................. 3

Channel Letter Manufacturing Process – 3M ................................................................. 4

Cost-Effective Thermoforming of a Wheelchair Seat – Ottobock .................................. 5

Waterproof and Dustproof Hearing Aid – Starkey ......................................................... 6

Dielectric Strength Test Stand – Lake Region Medical. .................................................. 7

Manual Breadfruit Peeling Mechanism – Rauenhorst Farm .......................................... 8

Patient Fall Prevention Device – Courage Kenny Rehabilitation Institute .................... 9

Injera Oven Redesign – Gelalecha & Mowry . ............................................................... 10

Interactive Sensor Zone Exhibit – The Works Museum ............................................... 11

Universal AC Voltage Flex Arm LED Spotlight – Banner ............................................... 12

Transparent Film Inspection System – Carestream ..................................................... 13

Modular Fixturing for 3D Metrology Systems – Productivity Quality ......................... 14

Smart Cup Hydration Measurement System – Headwaters Innovation ...................... 15

Sorghum Juice Concentration System for West Africa – ICRISAT................................. 16

Motion Control and Actuation of FDM T600 Prototype – Stratasys ........................... 17

Cable Driven Robot Demonstration Model – PAR Systems ......................................... 18

Thin Film Flexible Cooling Device – MINCO .................................................................. 19

Security Indicator for Fall Protection Harness – 3M ..................................................... 20

Dental Restorative Material Delivery System – 3M ..................................................... 21

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Magnetic Vascular Grafts

Team Devin Abel, Patrick Connelly, Joe Dunbar, John O’Rourke, and Fadumo Yusuf Clinic Advisor Brittany Nelson-Cheeseman Industry Representatives Dan Dragomir-Daescu, Sean McEligot, Brandon Tefft, Grupreet Sandu, and Susheil Uthamaraj

(Fadumo Yusuf, Joseph Dunbar, John O’Rourke, Patrick Connelly, Devin Abel) Project Summary Mayo Clinic is located in Rochester, Minnesota and provides health care to patients from 150 countries across the world. Mayo Clinic is a world leader in research and treatment of coronary heart disease, the number one cause of morbidity and mortality in developed nations. Coronary artery disease is routinely treated with bypass surgery, which requires the use of a vascular graft. Currently available grafts include

autologous vessels and synthetic grafts. A large number of patients would benefit from safer, more effective, and more available synthetic vascular graft technology. Previous research has shown that a porous and magnetically-endothelialized grafts allow for better integration and performance within the patient. The team integrated magnetic material in a mandrel dipping processing technique. Design Goal Create a working prototype graft with porosity, magnetic properties, and desirable mechanical properties for demonstrating feasibility in an in vitro model.

Design Constraints

• Graft must be made out of biocompatible components.

• Graft must attract paramagnetically labeled cells.

• Graft must have uniform porosity through the wall thickness for tissue growth.

• The graft must not kink at a bend radius of 1 cm.

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Light-Cured Conformable Polymer Stents

Team Sara Backlund, Nick Haugen, Noel Naughton, and Alex Schroeder Clinic Advisor: James Elingson Industry Representatives: Dan Dragomir-Daescu, Sean McEligot, Brandon Tefft, Grupreet Sandu, and Susheil Uthamaraj

Project Summary Current stents often create long term complications; they also prove to be challenging to deploy in various regions of the artery, such as bifurcations and tapering arteries. The concept of conformable stents has the potential to alleviate these complications, as well as allow for greater variation in stent geometry. Mayo Clinic wants a

proof-of-concept prototype stent delivery system predicated on a recent Mayo Clinic patent. This proof of concept will be 3X true scale and will be deployed in an in vitro model.

(Nick Haugen, Alex Schroeder, Sara Backlund, Noel

Naughton) Design Goal Create a stent filled with a light curable polymer resin (filler) enclosed by a thin polymer sleeve. This stent will be deployed in the artery with a medical balloon and then cured via a cylindrical light diffuser in the middle of the balloon.

Design Constraints

• Maximum blood vessel occlusion time shall be 2 minutes.

• After delivering the stent, the delivery system shall be removed from the blood vessel phantom.

• When the stent material is delivered, it shall avoid distal embolism.

• The delivery system shall be compatible with standard percutaneous coronary intervention techniques.

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Work Suit Cooling

Team Munthir Ali, Rashed Alkhaldi, Ryan Hilliard, and Sam Miller Clinic Advisor: Ravi Sura Industry Representatives Phillip Martin and Scott Purrington

(Rashed Alkhaldi, Sam Miller, Munthir Ali, Ryan Hilliard)

Project Summary 3M’s current 4510 and 4565 protective work suits are uncomfortable at elevated temperatures, but do not allow for ventilation of body heat. This results in workers taking breaks more frequently, decreasing productivity. In order to increase productivity and worker’s comfort, 3M’s Personal Protective Equipment division tasked the team with developing a cooling system for their disposable 4510 and 4565 work suits. The cooling system will use air, conditioned by water or a refrigerant, to decrease the temperature within the suit, and noticeably increase comfort. The final system

needs to be portable, requiring no external air or power lines to function. The final system is also to be designed with user ergonomics in mind. Defining a measurement for worker comfort in different activities provides a further challenge for the design team.

Design Goal Design a system that will cool off workers in a full-body suit and noticeably increase comfort and increase productivity.

Design Constraints

• Must remove heat from the user, using air as a cooling medium.

• Must increase comfort within temperatures of 75° F and 100° F.

• Must increase comfort within ambient relative humidity of 30% - 75%.

• Must be self-powered; independent of external cords.

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Channel Letter Manufacturing Process

Team Andrew Hanson, Derek Kuehn, Cody Luebeck, and Joe Millette Faculty Advisor Chris Haas Company Sponsor Ellen Aeling

Project Summary Channel letter signs are commonly used by businesses for advertising on the side of their buildings. 3M currently manufactures the thin films applied to the face of these letters to give the signs color. 3M asked the team to improve the manufacturing process of customized channel letters, focusing on making production faster and more cost-effective. 3M wants to take the improved method and show it to sign manufacturers with the goal of improving their overall sign production process. The team has developed a rapid-manufacturing process using a 3D printer tooling head which can be retrofitted onto any CNC table currently in the sign shops. The new process automates production,

increases throughput, and removes the use of hazardous chemicals and toxins. Design Goal Design an improved channel letter manufacturing process that will increase throughput of signs and reduce costs.

(Derek Kuehn, Cody Luebeck, Joe Millette, Andrew Hanson) Design Constraints

• The process must have the capability of creating custom fonts.

• The process must increase the throughput of signs.

• Production cost must not exceed that of the current process.

• The mechanical properties of the sign must meet or exceed the current standard.

• The overall appearance of a letter must not be altered.

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Cost-Effective Thermoforming of a

Wheelchair Seat

Team Andy Beard, Tom Hensley, Stu Lombardo, and Shehan Perera Faculty Advisor Chris Haas Company Sponsor Mike Phillips Project Summary Ottobock, a worldwide provider of prosthetics, orthotics and mobility solutions, creates custom wheelchair seats by using a thermoforming process. A foam sheet is heated in an oven and then conformed to a mold in the shape of the patient. The design team has been tasked with analyzing and improving the thermoforming process of the Ottobock Shape System™ (OBSS) Ortho-Shape wheelchair seat liners. Ottobock’s current thermoforming process produces a high defect rate, is difficult for operators to perform, requires an excess amount of operators and is not cost-effective. The team decided to address these difficulties and improve this process by developing a design comprised of three parts: preparing the foam sheet for heating, handling the foam sheet effectively and forming the foam sheet over the mold.

Design Goal The goal of this design is to reduce the amount of operators to two and to reduce the amount of defective products from ten percent to five percent by achieving uniformity in thickness of the seat liners post-thermoforming.

(Stu Lombardo, Tom Hensley, Andy Beard, Shehan Perera) Design Constraints The new process shall require no more

than two operators. Thermoformed foam sheets shall be

within tolerance and obtain uniform thickness throughout the product.

An accurate measurement of liner thickness shall be devised.

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Waterproof and Dustproof Hearing Aid

Team Dan Doran, Benn Hulbert, Andrew Maas, Robin Nault-Maurer, Tremayne Williams Clinic Advisor Robert Monson Industry Representatives Tom Bergner and Brian Dobson

(Benn Hulbert, Dan Doran, Tremayne Williams, Robin Nault-Maurer, Andrew Maas)

Project Summary The goal of this project is to develop a new housing for a current hearing aid device that will achieve an Ingress Protection (dust and water) rating of 68 while maintaining the functionality of the battery door and mechanical switch. The challenges of this project include designing

around the acoustic and battery requirements, as both require air to penetrate the device while maintaining a waterproof and dustproof seal. Starkey's goal is to boost market share in the waterproof hearing aid industry by introducing one of the first high quality waterproof and dustproof hearing aids. Design Goal To create a waterproof and dustproof case for the Starkey Xino Micro hearing aid.

Design Constraints

• Reuse internal components of the Starkey Xino Micro Ric device.

• Marginally larger device is acceptable (<5%).

• Prototype tooling must not exceed $35,000.

• Must not reduce current SPL by more than 3 dB.

• Must not reduce bandwidth less than 7k for a 115/50 SPL/Gain matrix.

• All materials must pass biocompatibility and cytotoxicity testing.

• Must not infringe on patents filed in the US, Europe, or Japan.

• Prototype must pass IP68 standard tests. • The Zinc-Air battery must receive the

required amount of oxygen to continue functioning.

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Dielectric Strength Test Stand

Team: Beth Annoni, Paul Cordes, Kevin Dease, and Alex Krause Clinic Advisor Christopher Greene Industry Representatives Maria Swenson and Jack Hines

(Beth Annoni, Paul Cordes, Alex Krause, Kevin Dease) Project Summary Lake Region Medical is a global leader in the medical device industry, specializing in minimally invasive medical devices. The company is expanding into the design and manufacture of finished medical-electrical devices. Our team designed a dielectric test stand that ensures the

insulation of these new devices is sufficient to protect the operator and patient, and is in compliance with the appropriate standards. Our team also designed and incorporated computer software that runs the dielectric test, reads the test results, and generates the corresponding test reports.

Design Goal Design a dielectric test stand verifies device compliance with the appropriate clause of the International Electrotechnical Commission 60601-1 technical standard.

Design Constraints

• Test equipment must be able to perform electrical tests on multiple types of devices.

• Test equipment must prevent harm to the user from electric shock.

• Test surface must have a dielectric constant of approximately 3.0 or less

• Test equipment must generate a test report.

• Test system must be able to accommodate additional test equipment in the future.

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Manual Breadfruit Peeling Mechanism

Team Majed Aljahdali, Keegan Bragg, Jay Denny, and Dustin Sherrill Clinic Advisor Tony Beck Industry Representative Larry Rauenhorst

(Keegan Bragg, Jay Denny, Majed Aljahdali, Dustin

Sherrill) Project Summary Third world countries are having trouble taking fullest advantage of the short breadfruit seasons, where 60-70% of the total breadfruit goes to waste. Currently, breadfruit is peeled by hand, a process that takes anywhere from 1.5 to 4 minutes for a single breadfruit. This fruit peeler will allow for faster peeling time and as a result

reduce the amount of wasted breadfruit. Our sponsor’s previous prototype, made out of recycled car and bicycle parts, is now working in Haiti. After looking at a video of that prototype in operation, the team was tasked to improve the initial design by reducing the number of adjustment points and ultimately make a second prototype out of readily available materials. Design Goal The goal of this project was to design a fruit peeler to peel fruits ranging from 4 to 8 inches in diameter in less than 15 seconds.

Design Constraints

• Must peel a fruit in less than 15 seconds. • Must have a manual power source. • Must be operated by a single person. • Must cost less than $200 to

manufacture.

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Patient Fall Prevention Device

Team Benjamin Danielson, Andrew Hirsch, Nicole Kroehler, and Adam Mahre Clinic Advisor Katherine Acton Industry Representatives Lars Oddsson, Brian LeLoup, and LeAnne Hammer

Project Summary Falls are among the most common and adverse events reported in hospitalized patients, especially patients in an acute rehabilitation unit with medical conditions that increase fall risk. Courage Kenny Rehabilitation Institute determined that a majority of these falls occur in

restrooms. Our solution is a device that prevents patients from falling off the toilet during use.

(Adam Mahre, Ben Danielson, Nicole Kroehler, Andrew

Hirsch)

Design Goal Design, test and prototype a device to keep high fall risk patients from falling while using the toilet. Design Constraints The prototype must

• accommodate patients weighing up to 500 pounds.

• not require nurses to lift more than 32 lbs.

• fit in Abbott Northwestern Hospital bathrooms.

• comply with restraint standard PC.03.05.19, EP 1.

• utilize an alarm system. • be made from cleanable materials. • take 15 seconds or less to be placed on a

patient.

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Injera Oven Redesign Team Zach Brintz, James Monson, Shawn Nevala, and Nathan Webster Clinic Advisor Camille George Industry Representatives Ame Gelalecha and Greg Mowry

(James Monson, Zach Brintz, Shawn Nevala, Nathan Webster) Project Summary The purpose of the injera oven (mittad) redesign project is to create a functional prototype injera cooker that will increase efficiency, reduce cost, and is capable of being assembled and manufactured in Ethiopia. Injera, a staple food eaten daily in Ethiopia, is similar to a thin pancake that is roughly 20’’ in diameter. The team focused

on creating a practical and economical electric powered injera cooker that will replace current models, which consume roughly 60 - 70 percent of the power in Ethiopia. The project was directed towards improving and redesigning the thermal and material properties of current cookers, along with achieving Ethiopian cultural acceptance of the new design.

Design Goal The main goal of this project was to reduce the power consumption of the injera cooker from 4.4 kW to 2 kW. Design Constraints

• Power consumption of 2 kW or less. • Temperature control. • 20 inch diameter cooking plate. • A method to release steam. • Non-stick surface. • Weight of 25 pounds or less. • Capable of being assembled in Ethiopia. • Cost of goods of $50 or less.

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Interactive Sensor Zone Exhibit

Team Anthony Domeier, Alex Hoffman, Hannah Larsen, and Gaylord Mubwa Faculty Advisor AnnMarie Thomas Company Sponsor Jill Measells

Project Summary The Works Museum is a children’s engineering museum, located in Bloomington, MN. It’s mission is to “inspire the next generation of innovators, engineers, and creative problem solvers.” The museum offers daily visits for families, hosts birthday parties, and facilitates classes for field trips. Their target age range is children ages 6-12. The Sensor Zone is an area of The Works Museum where children can interact with sensors and explore how they effect change on their environment. There are currently five interactive exhibits in the Sensor Zone. The

Works Museum requested an additional interactive exhibit installation to their Sensor Zone Exhibit. The team attempted to strike a balance between the robustness of the design and prototype and the entertainment and education value for children.

(Anthony Domeier, Alex Hoffman, Gaylord Mubwa, Hannah Larsen) Design Goal The design goal was to create a museum interactive that would be a seamless and valuable addition to Sensor Zone at The Works Museum. Design Constraints

• Include a sensor not currently used in Sensor Zone.

• Be interactive and engaging for children, ages 6-12.

• Be robust and durable. • Fit within a 10’ x 15’ designated area. • Installation must follow local building

code.

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Universal AC Voltage Flex Arm LED Spotlight

Team Members James Ericson, Thomas Hofmeister, Madeline Kreuser, Dylan Nelson, and Gary Vu Clinic Advisor Ranjan Chakravarty Industry Representative Chuck Dolezalek

(James Ericson, Dylan Nelson, Thomas Hofmeister, Gary Vu, Madeline Kreuser) Project Summary The design team developed a state-of-the-art LED Spotlight System that provides an all-in-one solution to meet the demand for a rugged and highly adjustable task lighting option suitable for industrial applications. The design maximized ease-of-use and ease-of-implementation for the end user. The spotlight system incorporates various mounting methods, allows for variable light intensity and variable spot size. It can be

powered by most standard AC voltages supplied through a standard wall outlet.

Design Goal To design a dimmable and focusable LED spotlight and a dedicated universal AC power supply unit. Design Constraints

• The power supply unit must accept universal AC input voltages and frequencies.

• The spotlight must allow for a manual focus adjustment to change the spot size.

• The spotlight intensity must be dimmable through a knob on the power supply.

• The whole system must be compatible with a variety of mounting options.

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Transparent Film Inspection System

Team Charles Kolstad, Joshua Metz, Christopher Nathan, and Matthew Westrum Clinic Advisor Todd Jones Industry Representative Robert Monson

Project Summary Carestream Health is in the process of developing a new transparent, conductive film called Flexx™ Film for use in touchscreen devices. This new product exhibits varying optical performance dependent upon different light sources incident at different angles. Carestream has challenged our team to develop a test system that can analyze the optical performance of a given sample of Flexx™ Film under different lighting conditions. This test system will provide Carestream with important information as they seek to improve their product.

(Joshua Metz, Christopher Nathan, Matthew Westrum, Charles Kolstad)

Design Goal Our goal is to provide Carestream with a test system that can characterize the transparency of a given sample of Flexx™ Film. This will be performed using interchangeable light sources capable of providing incident light at any angle between 30° and 60°. A camera will scan, capture and store images of film samples placed under these conditions for later analysis. Design Constraints The test system must:

• Accommodate any size film sample up to 12”x12.”

• Provide an easy-to-use interface for an operator.

• Cost less than $2500.00 to build. • Not damage the Flexx™ Film sample.

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Modular Fixturing for 3D Metrology Systems

Team Luke Bastiansen, Thomas Brezniak, Joe McCullough, and James Pierce Clinic Advisor Ranjan Chakravarty Industry Representative Keith Summers

(Joe McCullough, Luke Bastiansen, James Pierce, Thomas Brezniak) Project Summary Productivity Quality is a supplier of Coordinate Measurement Machines (CMMs). They have recognized that there is an opportunity in the marketplace for a low-cost solution to holding parts in place while they are being measured for quality control. To ensure that a part complies with required design specifications, critical dimensions must be measured. Regardless of which inspection system used, the measured part must be constrained within a three-dimensional space without distorting the measurements. To do this parts must be fixture

to achieve repeatable dimensional accuracy. The team has been tasked with designing a modular system that is capable of reaching these accuracies.

Design Goal To design a low-cost fixturing system that has modular part gripping capabilities.

Design Constraints

• Must eliminate costly threaded baseplate.

• Must be able to fixture parts in an infinite number of positions within working volume of a Coordinate Measuring Machine.

• Deflection must remain constant with respect to time.

• Must allow for modular base configurations.

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Smart Cup Hydration Measurement System

Team Jon Gorzycki, Derek Johnson, Bryon McCory, Bryan Thell Clinic Adviser Thomas Shepard Industry Representative Brian Bischoff

(Bryon McCoy, Jon Gorzycki, Bryan Thell, Derek Johnson) Project Summary Nearly $1.2 billion dollars are spent each year on potentially avoidable hospitalizations due to improper patient hydration. The Smart Cup accurately tracks hydration levels to reduce these costs. It will monitor the patient’s fluid consumption throughout the day and then visually prompt the patient on their hydration needs. The final deliverables of this project will be a bench-top prototype to prove that the concepts work, as well as a Smart Cup rendering of what the final product will look like. Smart Cup is a digital enhancement of the company’s existing Aquatally cup.

Project Goal Track an individual’s hydration within 6% of actual consumption.

Design Constraints

• The Smart Cup must measure water consumption within 6% for a standard 8 cups of water per day.

• The Smart Cup battery must last for 30 days under normal use.

• The Smart Cup must be hand-washable.

• The Smart Cup will use visual prompts to indicate user hydration needs.

• Hydration plans will be customizable for each user.

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Sorghum Juice Concentration System for

West Africa

Team Louis Kjerstad, Joseph Klinkhammer, Brendan O’Connell, and Zach Vaughan Clinic Advisor Greg Mowry Industry Representative Eva Weltzien-Rattunde

(Brittany Paterson, Colleen Raschke, Jamie Dziewic, Alex Arendt) Project Summary Sorghum stalk processing consists of two steps: crushing and concentration. The crushing squeezes the sugary juice from the sorghum stalks. The concentration step, which this project focused on, reduces the water content of the juice to yield syrup. The team worked with ICRISAT to develop a concentrator for use in the African nation of Mali, which currently does not practice sorghum stalk processing. Malian farmers will eventually use the concentrator and were directly involved in the design process. This

participatory approach allowed for material selection and a better understanding of customer needs and capabilities. With this research in mind, the team designed and built a concentrator that uses solar energy to evaporate water from the sorghum juice.

Design Goal: The goal of the concentrator design is to concentrate sorghum juice into sorghum syrup through the reduction of water content. Design Constraints

• Wood cannot be used as a fuel source. • Concentrator shall be socially acceptable

for women to operate. • Concentrator shall be transportable in a

donkey cart. • Locally producible in West Africa. • Must be Low-cost and durable.

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Motion Control and Actuation of FDM T600

Prototype

Team: Mohammad Bazara, Adam Dahlstrom, Zach Franz, and Tyler Herman Clinic Advisor: Kundan Nepal Industry Representatives: Brian Sabart

(Adam Dahlstrom, Tyler Herman, Zach Franz, Mohammad Bazara) Project Summary: Stratasys is a world leader in 3D printing equipment using fused deposition modeling (FDM), Polyjet, and smooth curvature printing (SCP) technologies. Stratasys manufactures a full suite of additive fabrications systems and materials that range from small desktop packages to large format machines. The company is looking to demonstrate the capabilities of the FDM process through a design and fabrication project. The company provided the University of

St. Thomas with a complete 3D-printed, static T600 replica that will be used in design shows once movement is achieved. The team incorporated many different actuation options, as well as user controls to provide a secure connection for remote control and the desired movements.

Design Goal To implement head, shoulder, and elbow motion through user controls to a static 3D-printed T600 replica. Design Constraints

• Main body needs to be constructed from 3D printed parts.

• Needs to have building blocks for future redesign.

• Must have remote user controls for human interaction.

• Needs to maintain balance while moving.

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Cable Driven Robot Demonstration Model

Team Devin Braatz, Timothy Dessonville, Alex Getting, Taylor Marsh, and Dalton Sherrill Clinic Advisor Michael Hennessey Industry representatives Jae Lew and Joel Howard

(Timothy Dessonville, Taylor Marsh, Devin Braatz, Alex Getting, Dalton Sherrill) Project Summary PaR Systems creates multiple robotics platforms to provide intelligent solutions in varied environments. Cable-driven robots are one of these platforms that provides an ideal delivery system for remote long-term projects. The design team is to create a working scaled model of PaR Systems’ cable-driven robot. The position of a mobile platform is controlled by the length of six cables. Given a desired position (x,y,z), a real-time controller running LabVIEW continuously

performs kinematic equations to determine the cable lengths necessary for the platform to reach the desired location. Six electric motors with position feedback rotate spools of cable until the lengths of line reeled in or released is equal to the desired cable lengths. A joystick allows a user to change the location of the mobile platform.

Design Goal The purpose of this project is to design, build, control, and demonstrate a scaled model cable-driven robot. The workspace of the robot is able to change, allowing PaR to develop and validate various tensile truss configurations to optimize a workspace for a given application. This model can be used as a demonstration piece for PaR Systems cable-driven robotic capabilities. Design Constraints

• Total material budget: < $4000 per model.

• 6 degrees of freedom motion. • 2’ x 1’ x 1’ max workspace. • Mobile platform must move in x,y,z

directions at 1 inch per second. • Weight of model must be less than 50 lbs.

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Thin-Film Flexible Cooling Device

Team Ryan McArdle, Chelsie Peterson, Jack Stangl, and Bryce Werkmeister Clinic Advisor Surya Iyer Industry representative Issac Remer

(Yu-chen “James” Li, Matthew Ruud, Samuel Clemens, Daniel Kassen)

Project Summary Minco is a global provider of sensors, flexible circuits, and thin-film heaters. Its current target markets include medical devices, defense, and aerospace. Customer demand is driving Minco to develop complete thermal solutions providing both heat generation and dissipation within the same thin-film device. Microelectronic components are becoming smaller and provide greater computing power, but their performance is limited by their inability to dissipate heat. Developing an efficient and cost effective thin-film flexible cooler will allow Minco to offer a complete thermal solution to customers. The team developed a testing methodology and system to prove the feasibility of the thin-film cooling technology. Project Goal The goal for this project was to research, test and validate a proof-of-concept for a thin-film flexible cooling device. Design Constraints

• Manufactured with Minco’s current manufacturing processes and materials.

• Remove 20 Watts/in2 at 100oC • Thickness less than 0.030” ± 0.005”.

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Security Indicator for Fall Protection Harness

Team Adam Backes, Arden Costello, Tonny Lukabya, and Anthony Suchla Advisor Bob Mahmoodi Industry Representative Parul Patel

Project Summary The design team was tasked with designing and incorporating an electrical safety system into a fall protection harness that will alert the user to improperly secured harness buckles. Our prototype involves an updated buckle design with a central control system (CCS) mounted on the harness. Each buckle includes a reed switch in the female end and a magnet in the male end. The reed switch makes contact when a magnetic field of a specified strength is present, and this approach enables the buckles to notify the central control system whether it is properly connected or not. The CCS then alerts the user the status of each buckle.

(Tonny Lukabya, Arden Costello, Adam Backes, Anthony

Suchla) Design Goals The electrical system is designed to notify the user the status of each buckle, as well as prompting proper donning. Not all users wear the fall protection harnesses correctly, and this project is designed to improve the safety of the work environment where a fall harness is necessary. Design Constraints

• The safety system shall be mounted to a fall protection harness so that it does not affect its usability while being able to withstand the environments that may be encountered in the workplace.

• The security indicator shall notify the user the status of each buckle, and it shall present visual and/or audio warning when a harness is buckled improperly.

• The total cost of each system must be less than $20.

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Dental Restorative Material Delivery System

Team Andressa Lunardelli, Brianna Nieson, Gino Pitera, and Drew Stangler Clinic Advisor Surya Iyer Industry Representatives Bruce Broyles, Darin Meyertholen, and Greg Schrank Project Summary The Filtek Supreme Ultra Universal restorative paste is a dental composite used for anterior and posterior dental procedures. Due to its composite nature, the material has a high viscosity that makes it difficult to handle and increases the procedure time. In order to overcome this high viscosity, heating can be incorporated into the delivery system to improve the material’s flowability, workability and curing rate. This desired flowability is achieved by increasing the dental paste temperature by only 5-10°C above room temperature.

(Gino Pitera, Andressa Lunardelli, Drew Stangler, Brianna

Nieson) Design Goal The goal is to enhance flowability of the material with precision and control, without damaging the product or harming the patient. Design Constraints • The dental paste must be heated 5 to 10°C

from the room temperature within 15 to 30 seconds.

• The material temperature must not exceed 40°C to not damage patient’s tooth pulp.

• The surface of the delivery system must not exceed 45°C to not burn patient and dentist’s skin.

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Thank you, Seniors!