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Manufacturing Engineering (1st)

These projects are at the midpoint of a two-semester sequence.  They are not complete.

Automation of Material Mating Process


Sponsor: CFAN

Student Team: Roger Faria, Christopher Watts, Jose' Ramos

Faculty Advisor: Dr. Austin Talley

CFAN is a joint venture between GE and SNECMA who manufactures composite fan blades used to power the Boeing 777. CFAN currently runs a 270,000 ft2 state of the art facility in San Marcos, Tx. Texas State University’s collaboration with CFAN is to find an innovative way to automate the process of mating materials 3M materials for construction on their new fan blade for GE9X turbofan engines . This new material will allow Boeing’s new 777X airliner to use fewer, thinner fan blades. Combined with the use of new composite case technology developed for the GEnx program, the engine will be around 1,000 pounds lighter than its predecessor. CFAN has requested that the team produce a thermal film mating machine capable of bonding rolls of adhesive and poly into one. The result of automating this process is a reduction in the number of set-ups required between each mating process as well as a reduction in cycle time.

Chain Wear Test Process Optimization


Sponsor:Intertek Automotive Research

Student Team: Zane Gooden, Brandon Sekula, Dieudonne Dusingizimana, Luis Ortiz

Faculty Advisor: Dr. Austin Talley

Intertek Automotive Research is an engine testing facility located in San Antonio, Texas that has the capability to test a broad range of engine types and sizes. Intertek is currently helping draft an ATSM standard for testing the chain wear for a 2.0L four cylinder Ford Eco-boost engine. This project focuses on control for engine dimensions and tolerances as well as increased repeatability, reduction of build time, and reduction of scrap rates.

Drifter 3.1 Project


Sponsor: NASA - Andi Thomas

Student Team: Dillon Lippe, Daniel Ceballos, Blake Daniel, Matthew Partridge

Faculty Advisor: Mr. Lee Hinkle

NASA mission statement for this year is to Discover, Explore, Develop and enable. In the Develop statement states that its overall goal is the address national challenges and catalyze economic growth. In doing so they hope to inspire the public in Space, Aeronautics and Science.

This project is focused on improving the Drifter 3.0 that was created by Texas State University in 2018. The Drifter is a device that is able to test water for temperature, pH, dissolved solids, and dissolved oxygen and that can be used for data collection in natural disasters such as hurricanes or in local waterways by hobbyists and school students. The project will be a combined effort by an Electrical Engineering team and a Manufacturing Engineering team and emphasis will be placed on creating a cost-efficient Drifter that meets NASA’s specifications and is easily replicated.

3D Tube Bender


Sponsor: Dustin Hardy, RH Systems

Student Team: Chris Resendez, Kevin Place, Quentin Scott, and Ben Paddock

Faculty Advisor: Dr. Austin Talley

RH Systems, located in Gilbert, Arizona, is a privately-owned company founded by Bob Hardy in 1998. RH Systems design, sell, and provide services pertaining to their state-of-the-art instruments that measure temperature, humidity, and sulfuric hexafluoride (SF6), along with precise humidity generators. The devices that RH Systems design provide solutions that are applicable to commercial laboratories, as well as a wide spectrum of industries such as electrical power, meteorology, environmental. Their products are manufactured in the United States and in Europe with their Switzerland partner, MBW. RH systems is sponsoring the manufacturing team from Texas State to design a machine that can bend small tubes into any desired shape so that the tubes can be implemented into their designs.

The 3D tube bending team has been tasked by RH Systems with designing and manufacturing a tool that can perform small diameter tubing into complex geometries. Currently, RH Systems does not have a machine capable of bending tubes in 3D for the desired diameter that they need. RH Systems has specified that the 3D tube bender must be able to bend 0.25” diameter of stainless steel and copper tubing with wall thicknesses ranging from 0.02” to 0.065”. The teams desired goal is to design and manufacture a useful automated 3D tube bender that can perform quality spiral and helix tube bends for RH Systems.

Penny Press Machine


Sponsor: Hunt & Hunt, LTD

Student Team: Nick Wood, Carson Patterson, Rafael Violante, John Ivey 

Faculty Advisor: Dr. Austin Talley

Texas State University, through ongoing development, has constructed Bruce and Gloria Ingram hall as an expansion of the Engineering Department. Ingram Hall serves to expand the existing Engineering class offerings, but also establishes a Makerspace available to students to bring ideas to life utilizing an assortment of 3d printers, laser cutters, CNC machines, and more.

Hunt & Hunt is a precision machine shop that specializing in perforating guns for the gas and oil industry. As a Texas State University Alma Mater (1978), Mr. Michael Bowman is a continuing contributor to the Texas State Athletics program, currently serves as a director of the Texas State Development Foundation and assists student athletes with the Bowman Family Endowment scholarship.

Given Mr. Bowman’s dedication to Texas State and the implementation of new utilities and technology available to students, a joint Senior Design project was created to showcase these technologies under the guidance of an experienced machine shop owner. The team is assigned to design and create in house a souvenir penny press machine utilizing as many of the machines available to demonstrate the Makerspace capabilities and commemorate the building. The project will span two semesters in which the students will design, prototype, and build the machine to be displayed for use in the Ingram Hall lobby.