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Rutgers UniversityDepartment of Mechanical & Aerospace Engineering2021-2022 Senior Design Projects14:650:467/468 Design and Manufacturing I/IIMechanical Engineering Projects1

Table of ContentsMechanical Fish. 4Wheelchair Modification . 6Multi-Mode Hybrid Unmanned Delivery System: Combining Fixed-Wing and Multi-Rotor Aircraft withGround Vehicles . 8Design and Testing of a Drone to Conduct Zero-G Experiments . 10Solar Powered Terrain Walker I . 12Solar Powered Terrain Walker II . 14Design of a Biomechanical Hand. 16Desktop-Size Non-Destructive Material Identification Device . 18Bio-Inspired Flapping Wing Energy Harvester I . 20Bio-Inspired Flapping Wing Energy Harvester II . 22Virtual Reality Cycling for Patient Rehabilitation . 24Automated Gantry System for Individualized Production . 26Solar Energy Harvesting or Water Desalination Device . 28Hybrid Manufacturing of Customized Knee Implant . 30Low-Cost Ventilators for COVID-19 Patients . 32Hybrid Solar and Wind Energy for a Practical Use Plus Storage . 34Table Top Subsonic Wind Tunnel . 36Color-Based Sorter . 383D Printer Capable of Printing Elastomeric Composites . Error! Bookmark not defined.3D Printer for Thermoplastics, Thermosets, Conductive and Metallic Materials . 40Detachable Propulsion Unit for Surfboards of Varying Size I . 42Detachable Propulsion Unit for Surfboards of Varying Size II . 44Dynamic Vibration Absorber . 46RFR Brake Dynamometer . 48Vacuum Tube Solar Steam Generator . 50Mechanical Device for Transdermal Drug & Gene Delivery . 52Gecko-Like Foot Pad . 54Gecko Robot. 56Equine Simulator . 582

Assistive Device for Wheelchairs/Scooters Users . 60Fishing Equipment with Sensory Feedback . 62High Strength, Light Weight Cylindrical Pressure Vessel with Fiber-Reinforced Composites . 64A Smart Fertilizer Machine for Urban Organic Waste Recycling . 663

ME PROJECT 1Mechanical FishAdvisor: Prof. Prosenjit BagchiEmail: pbagchi@soe.rutgers.eduProject Abstract: Conceptualize, design and build a device that swims like a fishProject Goals: Building mechanical fish-- an underwater device that can swim like afish using body undulations.Project Envisioned Outcomes: Design and fabrication of soft swimming devices.4

Students Expertise:NoneBeginner IntermediateDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)SeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediate 5SeriousHobbyistProfessional

ME PROJECT 2Wheelchair ModificationAdvisor: Prof. Haim BaruhEmail: baruh@soe.rutgers.eduProject Abstract: Wheelchair ModificationProject Goals: Giving a complex wheelchair capability to clean its wheelsProject Envisioned Outcomes: Using motorization and scraping techniques to makea wheelchair that has traveled on muddy surfaces clean itself before going indoors.6

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyist Professional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediate 7SeriousHobbyistProfessional

ME PROJECT 3Multi-Mode Hybrid Unmanned Delivery System: Combining FixedWing and Multi-Rotor Aircraft with Ground VehiclesAdvisor: Prof. Onur BilgenEmail: o.bilgen@rutgers.eduProject Goals: The goal of this project is to investigate novel concepts for a multimode unmanned aerial system. For example, a VTOL vehicle attached (docked) to afixed-wing (i.e. STOL) vehicle. In this case, the fixed-wing aircraft does the longdistance “cruising.” Once the system within the vicinity of the delivery location, themulti-rotor will detach and will take care of the vertical movement for a controlleddelivery to the ground. Navigation, planning, logistics, policy issues,docking/undocking, platforms etc. are all very interesting and relevant problems – suchissues will be looked at by the design team.Previous Success: The 2020 team received a research award from the highly competitiveNASA USRC program. ( pturesnasa-research-challenge ).The new team will apply to the same program in June. Inaddition, the 2020 Team presented a paper at the AIAA 2021 Region I Conference, andreceived the 3rd place prize in the team category.All team members are expected to have an exceptional work ethic and dedication to theproject. Students from all backgrounds who are interested in continuing to graduateschool are highly encouraged to join. Please contact Dr. Bilgen via email(o.bilgen@rutgers.edu) with the subject line starting with “Senior Design: Project Name– Your Name”.Project Envisioned Outcomes: See above.8

ME PROJECT 4Design and Testing of a Drone to Conduct Zero-G ExperimentsAdvisor: Prof. Onur BilgenEmail: o.bilgen@rutgers.eduProject Goals: The goal of this project is the design, analysis, fabrication and testingof a small quad-copter unmanned aerial vehicle (UAV) to act as a platform to conductZero-G experiments. The team will design, fabricate and test multiple iterations of thevehicle, as well as develop necessary control algorithms.Previous Success: The 2020 Team presented a paper at the AIAA 2021 Region IConference, and received the 1st place prize in the team category.The new team will apply to the highly competitive NASA USRC program in June. Iffunded, students will be able to conduct funded research during the academic year, orduring summer 2022.All team members are expected to have an exceptional work ethic and dedication to theproject. Students from all backgrounds who are interested in continuing to graduateschool are highly encouraged to join. Please contact Dr. Bilgen via email(o.bilgen@rutgers.edu) with the subject line starting with “Senior Design: Project Name– Your Name” .Project Envisioned Outcomes: See above.10

ME PROJECT 5Solar Powered Terrain Walker IAdvisor: Prof. William BottegaEmail: bottega@soe.rutgers.eduProject Abstract: Solar Powered Terrain WalkerProject Goals: design, analyze and manufacture a solar powered walking machineProject Envisioned Outcomes: design and blueprints, analysis and manufacture of awalking machine that can negotiate various terrains. There will be two teams that willcompete with one another for the best design. They will “race” against each other atthe end of the academic year.12

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediate 13SeriousHobbyistProfessional

ME PROJECT 6Solar Powered Terrain Walker IIAdvisor: Prof. William BottegaEmail: bottega@soe.rutgers.eduProject Abstract: Solar Powered Terrain WalkerProject Goals: design, analyze and manufacture a solar powered walking machineProject Envisioned Outcomes: design and blueprints, analysis and manufacture of awalking machine that can negotiate various terrains. There will be two teams that willcompete with one another for the best design. They will “race” against each other atthe end of the academic year.14

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediate 15SeriousHobbyistProfessional

ME PROJECT 7Design of a Biomechanical HandAdvisor: Prof. Kimberly Cook-ChennaultEmail: cookchen@soe.rutgers.eduProject Abstract: Design of a Biomechanical HandProject Goals: To design a robotic hand that incorporates both mechanical andelectrical functioning.Project Envisioned Outcomes: Incorporate of electronics for programmableexecution of movement of fingers.16

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision onal Additional Requirements and Information:Students will need experience with CAD and using arduino. Students will have ideallyhad a circuits class or similar experience to excel in this project.17

ME PROJECT 8Desktop-Size Non-Destructive Material Identification DeviceAdvisor: Prof. Alberto CuitiñoEmail: alberto.cuitino@rutgers.eduProject Abstract: To develop a desktop-size non-destructive material identificationdevice. This device will be based on mechanical testing of small samples. Elastic moduli(E) of the material will be obtained by recording the buckling load that for a givensample geometry and testing configuration, is only dependent on E. the By selectingthe geometry of the sample and loading condition, buckling can be triggered beforematerial material failure.Project Goals: To miniaturize a mechanical testing machine for buckling at relativelylow cost in such a way engineering students, with the proper design and documentation,can build their own testing device for testing material at home.Project Envisioned Outcomes: A tested machine design with a full set ofdocumentation for a DIY project for engineering students. The device should includeall the components of hardware, software and integration.18

Students Expertise:NoneBeginner IntermediateDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)SeriousHobbyist Professional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediateSeriousHobbyist 19Professional

ME PROJECT 9Bio-Inspired Flapping Wing Energy Harvester IAdvisor: Prof. Mitsunori DendaEmail: denda@rutgers.eduProject Abstract: Built on the latest in flapping flight research, the patent-pendingtechnology at the core of this project has been shown to produce efficiencies higherthan the best wind turbines on the market.How? Recently, scientists discovered that birds use advanced flapping aerodynamics tomove through the air up to 5 times more efficiently that man-made aircraft. The goalof this project is to use these recently discovered phenomena to efficiently harvestenergy from the wind. Team members will design and construct their own wind energyharvester, then test its performance under different conditions. They will have accessto CAD models of working prototypes that have been previously built and tested, andthey will also have access to proprietary MATLAB programs which can predictefficiency before building the device.Project Goals: Design of Bio-Inspired Flapping Wing Energy HarvesterProject Envisioned Outcomes: The students will have access to CAD models ofworking prototypes that have been previously built and tested, and they will also haveaccess to proprietary MATLAB programs which can predict efficiency before buildingthe device.20

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediate 7 21SeriousHobbyistProfessional

ME PROJECT 10Bio-Inspired Flapping Wing Energy Harvester IIAdvisor: Prof. Mitsunori DendaEmail: denda@rutgers.eduProject Abstract: Built on the latest in flapping flight research, the patent-pendingtechnology at the core of this project has been shown to produce efficiencies higherthan the best wind turbines on the market.How? Recently, scientists discovered that birds use advanced flapping aerodynamics tomove through the air up to 5 times more efficiently that man-made aircraft. The goalof this project is to use these recently discovered phenomena to efficiently harvestenergy from the wind. Team members will design and construct their own wind energyharvester, then test its performance under different conditions. They will have accessto CAD models of working prototypes that have been previously built and tested, andthey will also have access to proprietary MATLAB programs which can predictefficiency before building the device.Project Goals: Design of Bio-Inspired Flapping Wing Energy HarvesterProject Envisioned Outcomes: The students will have access to CAD models ofworking prototypes that have been previously built and tested, and they will also haveaccess to proprietary MATLAB programs which can predict efficiency before buildingthe device.22

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediate 7 23SeriousHobbyistProfessional

ME PROJECT 11Virtual Reality Cycling for Patient RehabilitationAdvisor: Prof. German DrazerEmail: german.drazer@rutgers.eduProject Abstract: This project will integrate mechanical engineering and rehabilitationscience. We want to design the next generation of the VRACK (virtual reality cyclingkit) system. It will contain sensorized pedals, handlebars and a heart rate monitor thatare interfaced with a virtual environment. The objective is to create an inexpensiveintegrated solution that is tailored for persons who have had a stroke and would use itin rehabilitation. For this project we collaborate with J. Deutsch, a professor of physicaltherapy in the Department of Rehabilitation & Movement Sciences at Rutgers.Project Goals: Design and manufacture a pedal that can be integrated into any bikeProject Envisioned Outcomes: A fully functional prototype to test in rehabilitationbicycles24

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginner 25IntermediateSeriousHobbyistProfessional

ME PROJECT 12Automated Gantry System for Individualized ProductionAdvisor: Prof. Xi GuEmail: xg107@soe.rutgers.eduProject Abstract: Development of an Automated Gantry System for IndividualizedProductionProject Goals: The objective of this project is to design and construct a fully automatedand flexible gantry system for individualized manufacturing/assembly. The systemshould be capable of picking, moving, and placing different items requested byindividual users (by controlling the speed of movement, etc.) The students will have theflexibility to formulate the design problem with specified applications.Project Envisioned Outcomes: A built gantry system with control.26

ME PROJECT 13Solar Energy Harvesting or Water Desalination DeviceAdvisor: Prof. Zhixiong GuoEmail: zguo@rutgers.eduProject Abstract: The amount of solar irradiation on earth’s surface is gigantic, butmost of which remains unutilized while we keep depleting traditional fossil fuels.Photovoltaic (PV) or solar cells convert light energy into electricity. The yearlyinstallation capacity of solar photovoltaic facilities has seen a continuous significantincrease worldwide in recent years. Solar energy is also used for natural illumination andwater and space heating. 97% of the water on the Earth is salt water. Water scarcity isamong the major problems to be faced by human beings. Solar desalination is atechnique to desalinate water using solar energy.In this project, you could bring in some “wild” ideas to harvest or use solar power. Forexample, you may consider harvest solar energy for illumination and water heating viaa smart window, build a small solar cell power generator, or design a solar desalinationdevice. The objective of this project is to design, build, and analyze a device for solarenergy harvesting or water desalination for engineering practice of natural renewableresources.Project Goals: Idea, analysis, design, device build, and test.Project Envisioned Outcomes: A device with some innovative or practical idea28

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediate 29SeriousHobbyistProfessional

ME PROJECT 14Hybrid Manufacturing of Customized Knee ImplantAdvisor: Prof. Yuebin GuoEmail: yuebin.guo@rutgers.eduProject Abstract: Students will design, manufacture, and testing a Customized KneeImplant through an integrative method.Project Goals: Learn and practice comprehensive knowledge in design concept,CAD/CAM, numerical simulation, manufacturing, and testing. Oral and writtencommunication and team skills are also emphasized.Project Envisioned Outcomes: Customized Knee Implant and written report30

ME PROJECT 15Low-Cost Ventilators for COVID-19 PatientsAdvisor: Prof. Yuebin GuoEmail: yuebin.guo@rutgers.eduProject Abstract: Students will design, manufacture, and testing a Low Cost Ventilatorfor COVID-19 Patients through an integrative method.Project Goals: Learn and practice comprehensive knowledge in design concept,CAD/CAM, numerical simulation, manufacturing, and testing. Oral and writtencommunication and team skills are also emphasized.Project Envisioned Outcomes: Functional Low Cost Ventilator and written report.32

ME PROJECT 16Hybrid Solar and Wind Energy for a Practical Use Plus StorageAdvisor: Prof. Yogesh JaluriaEmail: jaluria@soe.rutgers.eduProject Abstract: Use of hybrid solar and wind energy for a practical use plus storageProject Goals: Develop and test the designed systemProject Envisioned Outcomes: Fabricate and test the system and the design34

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediate 35SeriousHobbyistProfessional

ME PROJECT 17Table Top Subsonic Wind TunnelAdvisor: Prof. Doyle KnightEmail: ddknight@rutgers.eduMeeting Place: https://rutgers.webex.com/meet/ddknightProject Abstract: The project is the design, fabrication and demonstration of a tabletop subsonic wind tunnel measuring the lift and drag on an airfoil, air velocity,temperature and pressure.Project Goals: Completion and demonstration of the table top subsonic wind tunnel.Project Envisioned Outcomes: Demonstration of ability to design, manufacture andvalidate table top subsonic wind tunnel.36

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software er CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision programBeginnerIntermediate 37SeriousHobbyist Professional

ME PROJECT 18Color-Based SorterAdvisor: Prof. Hao LinEmail: hlin@rutgers.eduMeeting Place: https://rutgers.webex.com/meet/hlinProject Abstract: Design and manufacturing of a color-based sorter. Colorful objectsare detected by sensor, moved down a dispenser and sorted by a compressed-air-puffingmechanism.Project Goals: Design and manufacturing of a color-based sorter.Project Envisioned Outcomes: 1. Design and manufacturing capability. 2. Hardwareimplementation with sorting and object aligning mechanisms. 3. Algorithmdevelopment and integration with hardware.38

ME PROJECT 203D Printer for Thermoplastics, Thermosets, Conductive and MetallicMaterialsAdvisor: Prof. Rajiv MalhotraEmail: rajiv.malhotra@rutgers.eduMeeting Place: https://rutgers.webex.com/meet/rm1306Project Abstract: The project involves the integration of lasers and other light sourceswith an in-development 3D printer for printing thermoplastics, thermosets, conductiveand metallic materials within the same process. A setup has been developed in pastprojects for this process. This particular project will involve integration of a fiber-laserwith this setup to enable laser processing of these materials as well.Project Goals: The project involves the integration of lasers and other light sourceswith an in-development 3D printer for printing thermoplastics, thermosets, conductiveand metallic materials within the same process.Project Envisioned Outcomes: Integration of lasers and other light sources with anin-development 3D printer for printing thermoplastics, thermosets, conductive andmetallic materials within the same process.40

Students Expertise:NoneDesignAnalysisHand toolsTraditional MachiningCNC machining3D printingWeldingWiringSimple analog or digital electronics(e.g., resistors, capacitors, opamps)Microcontrollers (e.g., Arduino)BondingProcessing(e.g., vacuum bag, autoclave)Beginner IntermediateSeriousHobbyistProfessional Software WorksOther CAD packagesSiemens NXLabViewE-CalcAVLXfoilMachine vision program41IntermediateSeriousHobbyistProfessional

ME PROJECT 21Detachable Propulsion Unit for Surfboards of Varying Size IAdvisor: Prof. Aaron MazzeoEmail: aaron.mazzeo@rutgers.eduProject Abstract: Surfing requires a high level

May 22, 2021 · None Beginner Intermediate Serious Hobbyist Professional Design Analysis Hand tools Traditional Machining CNC machining 3D printing Welding Wiring Simple analog or digital el