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Manufacturing Engineering

RLC Blade Sharpening


Sponsor: Jacobs

Student Team: Rico Bendimez, Juan Hernandez, Alex Langlois, Citlali Morales

Faculty Advisor: Dr. Austin Talley

Technical Advisor: Dr. Namwon Kim

Jacobs company is a global provider of technical, professional, and scientific services that is subcontracted under NASA. Jacobs has over 230 locations around the world and serve a broad range of companies and organizations.

This project is focused on optimizing and improving a manufacturing process to sharpen the Reefing Line Cutter blades to certain specifications. Currently there are no standardized processes developed. The production of this process may be simulated, modeled, or prototype may be built.

Liquid Applied Sound deadener (LASD) Backup Inspection


Sponsor: Toyota

Student Team: Martin Veliz, Landry Neal, Patricio Lozano, Nicholas Gutierrez

Faculty Advisor: Dr. Austin Talley

Toyota Motor Manufacturing, Texas, INC. (TMMTX) is home to the Toyota Tundra and Tacoma pickup trucks. The Manufacturing process involves substantial operations and inspections for each stage of assembly and production. Vehicles passing through the painting stages of assembly receive a dampening coat to the vehicle floor in order to reduce noise, harshness, and vibration that enters a vehicle. The dampening coat, also known as liquid applied sound deadener, is applied in two segments by robots, and enters a backup area for inspection and manual repair/ reapplication. Current inspections require operators with extensive training to survey each vehicle and verify the correct application of LASD. The purpose of the project is to optimize the inspection process related to the application of a sound deadener by designing and utilizing a poke-yoke system.

3D Tube Bender


Sponsor: RH Systems

Student Team: Corbin Womack, Marisa Downey, Samantha Burkhart, Nick Loftis

Faculty Advisor: Dr. Austin Talley

RH Systems designs and sells temperature/humidity solutions used in premier chemical laboratories and meteorology institutes globally such as The National Institute of Standards and Technology, Texas Instruments, NASA, General Electric, Nissin, and Ford Motor Company. Currently, the bending of copper and stainless steel tubing is done by hand for these tedious operations.

This project is focused on designing a 3D CNC pipe bending machine capable of producing complex geometries such as helixes and spirals. This will address the consumer need for an automated, affordable way to bend tubing of a smaller diameter without the use of hand bending. The manufacturing team will be assigned to all manufacturing and mechanical aspects while the appointed electrical engineering team will focus on the electrical aspects.

ASTM D1384-05 Engine Coolant Corrosion Test Apparatus Optimization


Sponsor: Intertek Automotive Research

Student Team: Madeleine Jennings, Igor Shabatura, Matt Bordman

Faculty Advisor: Dr. Austin Talley

Intertek is an industry leader in independent automotive and petrochemical testing. The chemistry lab at the San Antonio location is capable of 450 different types of independent chemical analysis tests, including fuel and lubricant qualifications. Intertek San Antonio has teamed with Texas State University's Senior Design program to improve their engine coolant testing apparatus. This test must be performed in triplicate, as defined by ASTM D1384-05, and will expose metal coupons to coolant samples held at a constant temperature of 88℃ ± 1℃ for 336 hours, or two weeks. At the end of two weeks, the metal coupons are weighed, with the change in weight of each coupon indicating the level of corrosivity of the coolant being tested.

The current apparatus cannot provide the desired result turnaround or test reliability. It can only accommodate two sets of engine coolant, and the heating mechanism is inadequate for this application. The projected deliverables for this project include better heat distribution in the test bath, a larger testing capacity, and better reliability of test results. Additionally, the apparatus should be mobile for storage purposes, and safe to passers-by to prevent accidental burn injuries.

Solar Vehicle Chassis Design


Sponsor: Texas State University

Student Team: Luke Jaroszewski, Samuel Wright, Carl Hiltenbrand, Mohammad Alzaben

Faculty Advisor: Dr. Austin Talley, Dr. Richard Compeau

Technical Sponsor: Mr. Nathan England

The Solar Car Challenge is the top project-based STEM Initiative helping motivate students in Science, Engineering, and Alternative Energy. The SCC Education Program developed in 1993 as a high school extra-curricular program, and later evolved into the Solar Car Challenge Foundation.

This project focuses in the design and fabrication of the future solar car chassis. Students will use 3D modeling, FEA, and lean manufacturing techniques to ensure a competent product.

The future endeavors for this project are to compete in the solar car challenge and represent Texas State University for the first time in the school’s history at the famous Texas Motor Speedway

Perforating Gun Finishing Optimization

Sponsor: Hunt & Hunt, Ltd

Student Team: Tezra Berner, Justin Alcocer, Dominic Keeling, Eric Robinson

Faculty Advisor: Dr. Austin Talley

Hunt & Hunt Ltd (H&H) is a 100,000 sq. ft. manufacturing facility located in Houston, Texas that produces 20,000 perforating guns for the oil fracking industry per month. The company would like to increase their production from to 42,000 guns per month. Forecasts show demand to increase to 60,000 guns per month.

The Hunt & Hunt project is focused on optimizing the finishing and cleaning process of the perforating fracking guns to reduce the amount of time and labor. The current multi-step process is done manually; therefore, we will be doing extensive research to optimize the layout of the process. In addition, we will be making recommendation for a robot to Hunt & Hunt, so that they can potentially fully automate the process.