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ME 189/197 2012-13 Capstone Design Project List (rev 9/6/12)

Industry Partnered Projects

1. Spacecraft Mechanisms and Deployables Northrop Grumman (Faculty TBD)This project is in cooperation and partnership under a gift with Northrop GrummanAerospace Systems - Space Systems Division located in Redondo Beach, California.

Northrop Grumman Corporation is a $30 billion global defense and technology companywhose 120,000 employees provide innovative systems, products, and solutions ininformation and services, electronics, aerospace and shipbuilding to government andcommercial customers worldwide.

Northrop Grumman is a premier developer, integrator, producer and supporter of mannedand unmanned aircraft, spacecraft, high-energy laser systems, microelectronics and othersystems and subsystems critical to maintaining the nations security and leadership inscience and technology. These systems are used, primarily by government customers, in

many different mission areas including intelligence, surveillance and reconnaissance;communications; battle management; strike operations; electronic warfare; missiledefense; earth observation; space science; and space exploration.

Northrop Grumman Space Technology develops a broad range of systems at the leadingedge of space, defense and electronics technology. Building on a heritage of innovation,we create sophisticated products that contribute significantly to the nation's security andleadership in science and technology.

Project Description:

Mechanisms and deployables are an important aspect of any spacecraft design due to thelikely loss of the mission if a failure on deployment occurs. Students will design, build,

and test a deployment mechanism and payload that may be used on a CubeSat. Thestudents will demonstrate a mechanism design that will deploy a parabolic antennae froma CubeSat. The design of the mechanism and antennae must meet stringent stowagerequirements, launch load requirements, and strict deployed characteristics to ensuremission success. Typical driving parameters include size, mass, thermal environments,launch loads, and reliability. Verification of the design will also require students todevelop a test fixture to demonstrate their concept.

The company requires US citizenship for all site visits and a Confidential DisclosureAgreement.

Students with an interest in mechanisms and mechanical systems and an interest in the

aerospace industry will find this project demanding and technically challenging.

This project may require travel to company facility and may require periodicteleconferences.

Website: www.as.northropgrumman.com/index.html

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Figure 2. External View of typical Split Spool Device.

The mechanism described above requires extensive factory refurbishment after release,and is therefore impractical to use for preliminary testing. It would be very beneficial to

have a reusable device which has the same form factor and load capability as flight NEAdevices for ground test that does not need to be sent back to the factory to be re-set. Thestyle and type of release (manual-mechanical or electrical activation) for the reusabledevice is to be determined by the design team.

Tasks are as follows:

1) Develop and document device technical requirements including parameters such

as retention load capability, release time, release activation force (or electrical

impulse), re-set time, etc

2) Prepare a minimum of three release concepts in the early stages of the program.Only one concept needs to be developed beyond the conceptual stage

3) Create a physical mock up of the winning concept. The mock up should be a low

fidelity model, not to scale, with glue/rubber bands etc acceptable.

4) Create detailed engineering drawings for a reusable release mechanism

5) Perform a stress analysis on critical components

6) Manufacture and build the mechanism

7) Test the mechanism under tbd load tbd times

8) Deliver engineering drawings and a working prototype to ATK

CHALLENGE: Determine if design can be used in space, and determinechanges/testing needed for a fully qualified space rated mechanism.


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Implementation of this device is expected to greatly simplify testing which involvesrelease mechanisms. Consequently, this is a high visibility project for ATK GoletaOperations Management. Participants of this project will receive exposure to a variety ofspace flight manufacturing processes.

Students will be required to sign a Confidentiality Agreement and Invention Agreement.

Students are required to be a United States citizen for all facility site visits.

Website: www.atk.com

3. Camera Drive System FLIR (Faculty TBD)

This project is in cooperation and partnership under a gift with FLIR Systems located inGoleta.

FLIR Systems, Inc. is the global leader in Infrared cameras, night vision and thermalimaging systems. Our products play pivotal roles in a wide range of industrial,commercial and government activities in more than 60 countries. Pioneers in thecommercial infrared camera industry, the Company has been supplying thermographyand night vision equipment to science, industry, law enforcement and the military forover 30 years. From predictive maintenance, condition monitoring, non-destructivetesting, R&D, medical science, temperature measurement and thermal testing to lawenforcement, surveillance, security and manufacturing process control, FLIR offers thewidest selection of infrared cameras for beginners to pros.

Project Purpose:To create the drive system for a small pan-tilt camera that can be incorporated to a finalsystem using the Quark camera with a 35mm lens.

Problem FLIR has one of the smallest thermal cameras in the industry with

arguably the best image quality. However, FLIR has not produced asystem using this camera because it lacks a small motion control system.

Opportunity

Design a cost effective motion control pan-tilt system for one of thesmallest thermal cameras in the world.

This critical mechanical component will allow for the construction of oneof the smallest commercially available pan-tilt camera systems byenabling FLIR to develop only the electrical and software controlcomponents.

Project Scope:Design and demonstrate a prototype of a system that will both pan and tilt while housinga Quark 35mm Camera.

The system needs to be smaller than the M-Series(as small as possible).

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The system needs to meet FLIR Product line standards for maritime and security

products

The system should be cosmetically appealing. (no external screws)

The mechanical control system should have minimal backlash.

The mechanical control system should have repeatable motion control.

If possible, the system should be able to be controlled through a web browser

similar to the M-Series.

Students interested in designing and fabricating consumer products will find this to be ademanding and technically challenging project.

Student Requirements: Solidworks knowledge

Some understanding of electrical systems and control Thermal and dynamics expertise


Students are required to be a United States citizen for all facility site visits.

Website: http://www.flir.com/US/

4. Next Generation Anti Reflection Coating Fixturing For Infrared Sensor Chip

Assemblies - Raytheon (Faculty TBD)

This project is in cooperation with Raytheon Vision Systems, based in Goleta.

Raytheon Vision Systems develops and produces state-of-the-art detection and imagingdevices for applications in the x-ray, visible, infrared, terahertz and millimeter waveregions of the electromagnetic spectrum. RVS is well regarded as an intellectual andtechnological development leader. A complex of buildings that house developmentlaboratories, offices, and manufacturing facilities provide RVS with world classcapability for development and fabrication of top of the line sensing products. This RVSsite, located in Goleta, California, employs approximately 1,000 people with functional

organizations engaged in research and development, design engineering, andmanufacturing.

Students will have an opportunity to visit and work closely with industry engineers

responsible for the development of cutting edge next generation technology on site.

Project Purpose:

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This project is in cooperation and partnership under a gift with Medtronic Neurosurgerylocated in Goleta.

Medtronic Neurosurgery (MNS) is a local medical device company that is a leader in thefield of neurosurgical implants and devices. Medtronic is the global leader in medical

technology, alleviating pain, restoring health and extending life for millions of peoplearound the world. MNS is a world leader in the design and manufacture of implants anddevices intended to treat hydrocephalus.

Hydrocephalus is a buildup of fluid inside the skull that leads to brain swelling.Hydrocephalus means "water on the brain." Hydrocephalus is due to a problem with theflow of the fluid that surrounds the brain. This fluid is called the cerebrospinal fluid, orCSF. It surrounds the brain and spinal cord, and helps cushion the brain. CSF normallymoves through the brain and the spinal cord, and is soaked into the bloodstream. CSFlevels in the brain can rise if:

The flow of CSF is blocked

It does not get absorbed into the blood properly

Your brain makes too much of itToo much CSF puts puts pressure on the brain. This pushes the brain up against the skulland damage brain tissue.

Hydrocephalus may begin while the baby is growing in the womb. It is common in babieswho have a myelomeningocele, a birth defect in which the spinal column does not closeproperly.

Long-term implants known as Shunts have been used to treat hydrocephalus for morethan 50 years. The devices allow excess cerebrospinal fluid to drain to another area of thebody. A Shunt usually consists of two catheters and a one-way valve. The valve regulatesthe amount, flow direction, and pressure of cerebrospinal fluid out of the brainsventricles. As the pressure of cerebrospinal fluid inside the brain increases, the one-way

valve opens and the excessive fluid drains to the downstream cavity.Typically, the fluid gets "shunted" (moved) using the following shunt types:

A ventriculoperitoneal shunt moves fluid from the ventricles of the brain to theabdominal cavity

A ventriculoatrial shunt moves fluid from the ventricles of the brain to a chamberof the heart

A lumboperitoneal shunt moves fluid from the lower back to the abdominal cavity

A Fixed Pressure Valve is designed to regulate the flow rate of cerebrospinal fluid basedon a predetermined pressure setting.

Since the cost of shunt systems is beyond the reach of most people in developing

countries, most people with hydrocephalus die without even getting a shunt. A study doneby Dr. Benjamin C. Warf compares different shunt systems and highlighting the role oflow cost shunt systems in most of the developing countries. This study has beenpublished inJournal of Neurosurgery: Pediatrics May 2005 issue.

Project Description:The purpose of this project is to design a low cost fixed pressure valve that may beincorporated into a low cost shunt system for use in developing countries. The design


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must identify the use of readily available materials and manufacturing methods. Thedesign must comply with all international regulatory test standards for shunts

Project Scope:One of the outcomes of the project should be functional prototype of a fixed pressure

valve that satisfies international regulatory test standards. The valve design should allowfor different fixed pressure values, e.g. low, medium and high pressure versions of thesame valve. The valve should be fabricated of acceptable implant materials that may beincorporated into a shunt implant system. It is anticipated that special attention regardingassembly and test methods to address low cost manufacture must be included in thedesign.

Students interested in the medical industry will find this project interesting andchallenging. This is an opportunity to work with industry engineers, scientists andmarketing executives.


Website: http://www.medtronic.com and http://www.medtronic.com/our-therapies/hydrocephalus-products/index.htm

6. Syringe Filling System Applied Silicone (Faculty TBD)

This project is in cooperation and partnership under a gift from Applied SiliconeCorporation.Applied Silicone Corporation, based in Santa Paula, a leading producer of silicone,supplies raw material and technical and regulatory support to manufacturers of FDAregistered long term implantable devices used in neurological, orthopedic, urological,cardiovascular, reconstructive and general surgery.

Background

There are many commercially available syringe filling machines. These systems fail toaddress issues with handling silicone materials. Existing suck-back technology does notprovide an adequate break in the product stream when preparing to fill the next syringeleading to inaccuracies in metering and inconsistent dispensing. Hence, this currentsyringe filling technology is labor intensive and results in a substantial amount of wasted

product.

Project Description

This project combines the key engineering practices of good mechanical design,hardware specification, contamination control, electronic control interfacing, computerprogramming, and quality control.

http://www.medtronic.com/http://www.medtronic.com/our-therapies/hydrocephalus-products/index.htmhttp://www.medtronic.com/our-therapies/hydrocephalus-products/index.htmhttp://www.medtronic.com/http://www.medtronic.com/our-therapies/hydrocephalus-products/index.htmhttp://www.medtronic.com/our-therapies/hydrocephalus-products/index.htm

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Engineering Deliverables:

When completed, the system must be tested with the actual silicone components:The system will be supplied silicone from a SEMCO cartridge dispenser.

It must be able to accurately meter and dispense volumes between 2 and 100 cm3.

The system should be automated to minimize the amount of operator interactionfor filling and syringe assembly.

It will need to be designed such that it can be easily disassembled and cleaned forproduct change over.

The final system appearance should reflect its commercial viability.

Student Requirements:

Must be students in good standing with US Citizenship or valid Student GreenCard.

This project may require travel to company facility in Santa Paula.

A signed Nondisclosure agreement (NDA) is also required.

Students interested in designing and developing a production-ready system or equipmentwill find this project to be demanding and challenging. Students interested in ProcessEngineering and Industrial Engineering should find this project challenging andrewarding.

Ideal candidates will be skilled in mechanical design using SolidWorks and in executingthe design into a working hardware prototype including appropriate PLCinterfaces for remote operation.

It should be noted that a successful design will be commercially viable. Students will berequired to sign a Non-Disclosure Agreement and any successful design resulting fromthis project will be licensed to Applied Silicone Corporation without fee.

Website: www.appliedsilicone.com

7. Eye Model Test System for Intraocular Lens Materials Applied Vision Systems

(Faculty TBD)

This project is in cooperation with Advanced Vision Science Inc. (AVS), based in Goleta,California. Advanced Vision Science, Inc (AVS) is a medical device company with aglobal presence. Its core businesses are research and development and the manufacturingof implantable medical devices including intraocular lenses (IOLs) for cataract surgery.

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Cataract (clouding of the crystalline lens) is currently the leading cause of blindnessworldwide. Treatment consists of a routine surgical intervention that is successfullyperformed millions of times each year. During refractive lens exchange surgery, thecrystalline lens is replaced with a manufactured lens to provide an acceptable level of

visual acuity.

New intraocular lens designs in the market currently provide high-quality of vision, long-term stability, and independence from spectacles. Innovative designs in developmentoffer the promise toward restoration of accommodation. Development of accommodativeIOLs requires in-vitro models and testing systems to characterize changes in mechanicaland optical performance.

Project Description

The project goal is to develop an IOL test system compatible with cameras and various

measurement tools to gain a functional understanding of the mechanical and opticalproperties of various intraocular lenses. The system must be able to perform compressionforce, contact angle, and other testing of IOLs in-line with relevant ISO standards. AVScurrently has manual systems for all the tests the project system is intended to perform.The IOL test system must be enclosed in a wet cell model of variable diameter forholding various size lenses, in-line with relevant ISO standards.

Teams should expect to use SolidWorks for part and assembly drawings. Characterizationof intraocular lenses will be performed using high efficiency cameras/slit-lamp,microscopes, and wavefront sensor measurement devices available at AVS.

A functional understanding of the physiology of the human eye relevant to themechanism of vision is crucial to the successful implementation of this test system.

Students interested in state-of-the-art test equipment, systems, and test methods will findthis project demanding and challenging.

Participants will be asked to sign a confidentiality and invention assignment agreement.

Website: www.advancedvisionscience.com

8. Mechanical Clutch Release Bone Screw Driver Nuvasive (Faculty TBD)

This project is in cooperation and partnership with NuVasive located in San Diego.

NuVasive is a bio-medical company founded in 1997 on a commitment to develop bettersurgical solutions for spine patients. Today, NuVasive continues to revolutionizeminimally disruptive surgical solutions, allowing surgeons to treat spine conditions whileminimizing the surgical trauma experienced. NuVasive procedures have consistentlygarnered exceptional results shorter surgical times, less tissue damage, less blood loss,quicker release from the hospital, and a more rapid return to normal activities.

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The majority of the spine market is concentrated on fixing the degeneration of discs.Other problems include but are not limited to: tumor, trauma, infection and instability.NuVasives business is centered around a unique and nominal spine surgical techniquethat revolutionized the way in which surgeons address and tackle these problems. As

opposed to a typical anterior (front) or posterior (back) surgical approach, NuVasivebecame the pioneers of a patented, lateral (side) surgical procedure. This procedure,known as XLIF (Extreme Lateral Interbody Fusion), permits safe and easy access to thelateral aspect of the spine while preventing excess blood loss and limiting the morbidityof the surgery (resulting in quicker patient recovery).

A common problem in surgery is coming in contact and harming nerves en route to thespine. Therefore, a key compliment to the XLIF procedure is a nerve detection system.This device works with the XLIF instrumentation, reading electrical signals from thenerves that send audible feedback to the surgeon. The audible feedback allows thesurgeon to dictate his instrument location with respect to surrounding nerves. This way,

the surgeon can find the safest route to the spine without damaging any nerves.

NuVasive is the fourth largest spine company with top competitors such as Medtronic,DePuy, and Stryker. Their portfolio includes products for the cervical, thoracic andlumbar spine as well as the previously mentioned nerve detection system. NuVasive hasmore than 1,000 employees world-wide and is located in San Diego, CA.

Project Background:

A cervical plate is a spinal implant used during what is referred to as an ACDF (anteriorcervical discectomy and fusion) procedure to provide neck stability (like an internal,permanent cast), enhance fusion rates and minimize the need for a neck brace following

surgery. More information regarding how the product is used is available online viaGoogle ACDF surgery searches.

DESIGN BACKGROUND: To help achieve fusion between two vertebrae, a cervicalplate must be rigidly fixated to the vertebral bodies; fixation is achieved via bone screws.Bone screws are similar to machine screws; however, they usually have custom threadforms and drive features and are made of biocompatible materials (i.e. titanium alloy).Surgeons use a variety of hand-driven screw drivers to implant these bone screws. Thesemanual drivers enable precise control of location and depth of the bone screw but can betedious and time consuming to use. A drill-powered driver option may be preferred.

Project Proposal:

Students must propose a design for a Powered Bone Screw Driver surgical instrument.The driver must attach to and retain a cervical bone screw (to be provided). Below is alist of specific requirements:

1. Torque Release/Clutch Feature:


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a. To prevent stripping or over tightening of the screw, the instrument

must automatically stop driving the screw 2mm prior to contacting the

cervical plate (despite continuous torque input from the drill i.e. like

the clutch in a car).

a.i. Must be able to accommodate multiple screw lengths (12-18mm, 2mm increments).

2. Screw Retention:

a. The driver tip must engage and retain a bone screw, and easily release

it once placed.

a.i. Must have retention strength of 0.5 lbs.

3. Torque:

a. The instrument must withstand 15 in.lb. of torque.

b. Students must choose a drive feature (i.e. phillips head, square head,

hex, etc.) for the bone screw.

4. Material Selection:

a. The instrument must be manufactured using surgical grade stainless

steel.

Students must conduct relevant patent research as well as benchmark current products inorder to provide a viable design proposal. ASTM standards and FDA regulations shouldalso be considered when working with medical instruments and devices.

Prototype/Proof of concept expectations:

Students must provide complete CAD package including drawings and models.

Students may provide CAD models in .STP format to have NuVasive SLA 3D

print proof of concept.

Students must prototype individual mechanisms as one full assembly or as

separate sub-assemblies in order to perform testing.


Research Partnered Projects


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9. Mobility Cart for ICU Patients Santa Barbara Cottage Hospital (Laguette)

It in intended that this project will be supported by an NIH grant for Team-Based Designin Biomedical Engineering Education

This grant will directly support undergraduate team-based biomedical design projectscreated through UCSBs Department of Mechanical Engineering (ME), Department ofElectrical and Computer Engineering (ECE), and the Center for Bioengineering (CBE)with the Santa Barbara Cottage Health System (SBCHS), a provider of acute hospitalcare to the greater Santa Barbara region. Critical elements of this program are that eachproject will have a direct connection to immediate, local clinical needs, and that eachproject requires that the students merge their mechanical, electrical and biomedicalengineering expertise with the medical insights of our clinical mentors. This will providestudents with a unique learning experience that mimics the integrated approaches ofengineers working in the biomedical industry. Importantly, these projects will provide thestudent and team to be immersed in the clinical environment, developing an

understanding and appreciation of therapies, treatments, health care delivery, and qualityof life concerns. Through this award, the biomedical components of existing Capstonecourses will be expanded, to include clinically-relevant biomedical design projects jointlycreated by our students and by university and hospital faculty and staff. Under the jointsupervision of a UCSB faculty advisor and SBCHS mentor, students will work inmultidisciplinary teams of three to five (consisting of undergraduate majors in ME andECE, as well as Bioengineering concentrators in our College of Creative Studies) totackle a significant design and build project from concept through project completion anddevice delivery.

Project Description

Critically ill patients are typically treated in the Intensive Care Unit (ICU) of a hospital.New technologies in critical care have led to long-term survival of critically ill patients.An early mobility and walking program has been developed for ICU patients. Prolongedstays in the ICU are associated with functional decline and increased morbidity, mortality,cost of care, and length of hospital stay. Implementation of an early mobility and walkingprogram could have a beneficial effect on all of these factors. An early mobility programencompasses progressive mobilization and walking, with progression based on a patientsfunctional capability. Mobilization and the ability of an ICU patient to walk is alsolimited by the required equipment needed to provide care for the patient includingmonitoring equipment, infusion pumps, oxygen, suction, chest tubes, and catheters. It isdesired to design and develop a functional prototype of a cart that will allow the use of allnecessary equipment while connected to an ICU patient during mobility and walking.This Mobility Cart for ICU Patients should enable patients to be proactive in theirrecovery.

It is desired that a functional prototype will be developed for laboratory testing andevaluation only. The cart is not intended for immediate patient use.


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A simple system has been developed and is described in the following video:http://www.youtube.com/watch?v=RMSvWhQLIz0

This project will be clinically mentored by Jeff Fried, MD, Director, Critical CareMedicine of Santa Barbara Cottage Hospital. He is a specialist in Pulmonary and Critical

Care Medicine, who became the full-time hospital ICU Director at Santa Barbara CottageHospital in August, 2004. He is Board Certified in Internal Medicine, Critical Care, andPulmonary Medicine.

The student team may be comprised of ME students as well as interested Bioengineeringconcentrators in the College of Creative Studies.

10. Wireless Alarm Systems for the ICU Santa Barbara Cottage Hospital

(Faculty TBD)

It in intended that this project will be supported by an NIH grant for Team-Based Designin Biomedical Engineering Education

This grant will directly support undergraduate team-based biomedical design projectscreated through UCSBs Department of Mechanical Engineering (ME), Department ofElectrical and Computer Engineering (ECE), and the Center for Bioengineering (CBE)with the Santa Barbara Cottage Health System (SBCHS), a provider of acute hospitalcare to the greater Santa Barbara region. Critical elements of this program are that eachproject will have a direct connection to immediate, local clinical needs, and that eachproject requires that the students merge their mechanical, electrical and biomedicalengineering expertise with the medical insights of our clinical mentors. This will providestudents with a unique learning experience that mimics the integrated approaches ofengineers working in the biomedical industry. Importantly, these projects will provide thestudent and team to be immersed in the clinical environment, developing anunderstanding and appreciation of therapies, treatments, health care delivery, and qualityof life concerns. Through this award, the biomedical components of existing Capstonecourses will be expanded, to include clinically-relevant biomedical design projects jointlycreated by our students and by university and hospital faculty and staff. Under the jointsupervision of a UCSB faculty advisor and SBCHS mentor, students will work inmultidisciplinary teams of three to five (consisting of undergraduate majors in ME andECE, as well as Bioengineering concentrators in our College of Creative Studies) totackle a significant design and build project from concept through project completion anddevice delivery.

Project Description

Critically ill patients are typically treated in the Intensive Care Unit (ICU) of a hospital.These patients are connected to sophisticated monitoring and infusion systems with

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critical care life sustaining performance parameters. Many of the critical care systemshave alarm systems that are activated based upon clinical needs. These alarm systems arerequired for appropriate nursing care and health care delivery. This creates a noisyenvironment for the patient in the room. It is desired to improve the noise levels in patientrooms with the development of a wireless alarm system for personal hand-held devices to

alert nursing care.

It is desired that a proof-of-concept prototype will be developed for laboratory testing andevaluation only. The system is not intended for immediate patient use. It is envisionedthat this proof-of-concept prototype will be a simple infusion system with well-definedcontrollable parameters linked with an alarm system. The alarm system will be wirelesslylinked to a personal hand-held device (.i.e. Android Smartphone).

This project will be clinically mentored by Jeff Fried, MD, Director, Critical CareMedicine of Santa Barbara Cottage Hospital. He is a specialist in Pulmonary and CriticalCare Medicine, who became the full-time hospital ICU Director at Santa Barbara Cottage

Hospital in August, 2004. He is Board Certified in Internal Medicine, Critical Care, andPulmonary Medicine.

The student team may be comprised of ECE students, ME students as well as interestedBioengineering concentrators in the College of Creative Studies. Due to the expectedcomplexities of this project regarding wireless connectivity, this project will require ECEstudents on the team to address these efforts.

11. Marine Hydrocarbon Vent Gas Sampler D. Valentine Lab (Faculty TBD)

This project will be under the direction of Prof. David Valentine and Frank Kinnaman ofthe Marine Science Institute and Earth Science Dept.

Background and project purpose

The D. Valentine Lab is active in research concerning the biogeochemistry andgeomicrobiology of environments surrounding marine hydrocarbon seep vents. Coal OilPoint is the site of one of the largest of these natural systems in the world and is thesource for the tar seen on local beaches. A large component of these hydrocarbonreleases is natural gas. It is estimated that nearly 80 tons of methane is released into thewaters and atmosphere overlying the Coal Oil Point seep field (seeps at ~80m depthapprox. 1km offshore).

Description, pics and video:http://methane.geol.ucsb.edu/Home.htmlhttp://methane.geol.ucsb.edu/Movies.html

http://methane.geol.ucsb.edu/Home.htmlhttp://methane.geol.ucsb.edu/Movies.htmlhttp://methane.geol.ucsb.edu/Home.htmlhttp://methane.geol.ucsb.edu/Movies.html

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The Valentine Lab also investigates methane release in deeper marine settings includingthe Santa Monica Basin (~1000m depth), Santa Barbara Mid Channel Trend (~200mdepth) and Gulf of Mexico. Due to the high pressures and low temperatures methane canalso take a solid methane hydrate form at these depths. This research at deeper sites isconducted on biennial research cruises using the deep sea vehicles Alvin or Jason aboard

the Atlantis, the nations premier oceanographic research vessel. The next cruise isscheduled for October of 2013.Videos:http://www.youtube.com/watch?v=SiIqDLqY5TIhttp://www.youtube.com/watch?v=zIPsRv--dBQ&feature=channel&list=UL

Project description:We need to address some concerns in a current model of our underwater gas samplers, amodel developed and on semi-permanent loan to us by researchers at USC. Althoughthese samplers have served successfully for 3 major research cruises they have someinherent weak points and the overall performance of these gas samplers has markedly

deteriorated necessitating a redesign. Instead of simply refabricating the same samplerwith more robust parts we propose changing the fundamental sampling method to allowfor better isolation of the sample from contamination. The completed device will also bemodified as part of this project to mate with an existing methane hydrate flux measuringdevice for the deeper (>700m) settings.

It is very likely that at least a subset of students involved in this project will be invitedalong for the entirety or a portion of the 2.5 week SEEPS 2013 research cruise inoctober 2013 aboard the Atlantis (exact dates TBA), with preference for students whohave not yet graduated but with consideration for graduates as well.The ideal students will have some fabrication experience.

For further detail the following is a survey of the features of the previous model and theproposed project. Please direct questions to Frank Kinnaman([email protected]).

USC MODEL (EXISTING MODEL) STRENGTHS:1. The central mechanism of the device (displacement of degassed water by incoming gas)

is a valid way to fill the device without creating a dangerous overpressure in the sampler.

2. Volume (500mL) is probably about right to be able to distribute gas among replicate

samples and purge the transfer syringes.

3. No valve turns needed by Alvin/Jason.

USC MODEL SHORTCOMINGS:1. The two ports in and out of the chamber are simply 3 way syringe valves glued into place

fragile.

2. The most disturbing failure point is at the internal connection of the funnel with the

internal tygon tube of the unit immediately above the base plug point. It is very hard to

repair failures in this area.

3. The baseplate inverted stopper method - whereby the base plate acts to seal the unit

during deployment and recovery is a major flaw. If the baseplate stopper and inner

http://www.youtube.com/watch?v=SiIqDLqY5TIhttp://www.youtube.com/watch?v=zIPsRv--dBQ&feature=channel&list=ULmailto:[email protected]://www.youtube.com/watch?v=SiIqDLqY5TIhttp://www.youtube.com/watch?v=zIPsRv--dBQ&feature=channel&list=ULmailto:[email protected]

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surface of the funnel do not mate perfectly the degassed water in the portion of the

tube preceding the collection chamber leaks and air enters the collection tubing

preceding the sample chamber.

4. Funnel material is brittle plastic which chips and breaks fairly easily.

5. Main sampling chamber is mostly inaccessible.

6. Pre-filling the chambers with degassed water is somewhat tedious especially removing

the very last bubbles preceding the mouth of the 3 way valve exiting the chamber.

7. The only feature which keeps the sample from being contaminated with atmospheric or

dissolved gas is a short section of tubing filled with seawater at the exit of the sampler.

USC Model

USC Model showing a common point of failure

12. Morphable Membrane Mold System Lubin Lab (Faculty TBD)

This project will be under the direction of Prof. Philip Lubin of the Physics department.

Precision optics elements are critical for many applications from ophthalmology tocosmology. The application here requires extremely lightweight and precise optics thatcan be replicated which requires the use of a negative mold. It can cost hundreds ofthousands of dollars to machine a high precision mold for optical elements. For caseswhere multiple unique molds are required for production, the cost can becomeprohibitive. Cost can be reduced significantly by replacing the expensive rigid moldswith a single mold capable of morphing its surface into each required shape. The


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morphable mold system (MMS) is designed to bend a thin, flat plate into the neededshape using linear actuators. The deformed plate can then be used as a mold surface forconstructing carbon-fiber-reinforced polymer (CRFP) panels. Hundreds of uniquelyshaped CRFP panels are required to build large telescope mirrors. Theoretically, a singleMMS will be capable of molding every CRFP panel into its proper shape. Preliminary

testing of the MMS prototype has provided a limited proof-of-concept.

The goal of this project would be to design and develop further refinements andimprovements of the MMS with electronically activated linear actuators that arecontrolled by Labview with a variety of plate materials. Project outcomes would includethe selection of an optimum plate membrane material, the identification of predictivedeformation metrics within defined accuracy limits, and demonstrated use of the MMS inproducing unique CRFP test samples.

Students interested in working in a challenging and exciting research environment willfind this project of interest. Significant technical challenges are expected in FEA

modeling and testing of membranes under stressed edge conditions, metrology ofsurfaces and use of metrology test systems, algorithms to optimize surfaces andreplication techniques using CFRP on molds.

Independent fund raising efforts including an URCA grant will be necessary to supportproject efforts.

13. Vacuum Pump Acoustic and Vibration Enclosure Turner Lab (Faculty TBD)

Background: The small vacuum pumps that are ubiquitous in research labs create adisturbing amount of noise, as well as vibration that is carried through the vacuum linesto sensitive experiments.

Goal: Design and build a prototype enclosure that:Reduces the noise level to an acceptable level

Isolates, using a large mass, the pump vibration from the experiment

Is easily moved around the lab

Incorporates a cooling system to prevent the pump and motor from overheating


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An automatic over-temperature shut off.

Is modular allowing the enclosure to be fabricated in different sizes to accommodate

different vacuum pumps.

Commercial Opportunities: Labs all over the world need this type of enclosure, and thedesign team is encouraged to develop their ideas into a commercial product.

Notes:The team will be given a vacuum pump that is typical of those needing enclosures to

work with during the school year.

Contact Dave Bothman, [email protected] if you have questions about this

project.

Funds to support this project are available.

14. Precision Alignment Stage for MEMS measurements Turner Lab (TBD)

Background: Most of the measurements made in the Turner lab utilize laser-basedinterferometers that measure the displacement and velocity of vibrating microstructures.The devices are placed in a variety of sample holders that allow researchers to control gasmixture, pressure and temperature of the environment around them. Because themicroscope objectives have a small depth of field, it is important that the sample plane beparallel to the image plane of the microscope.

Goal: Design and build a manually-adjustable stage upon which researchers will place

their experiments. The stage should:Allow fine adjustments of pitch, roll and height of a platform approximately 12 x 12.

Support a 10kg platform

Provide a range of motion of +/-3 degrees in pitch and roll and 5mm in z.

Notes:This project will provide students with experience in precision machine design an

important specialty within mechanical engineering that is in great demand in the optics,

semiconductor and medical instrument industries.


project.


15. Vacuum chuck for microfluidic device assembly - CNSI (Faculty TBD)

mailto:[email protected]:[email protected]:[email protected]:[email protected]

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Background: Microfluidics is a technology involving the fluid mechanics with channelshaving micron-scale dimensions. Microfluidic devices are used in energy, chemistry,physics, biology and medical research. They are incorporated in many cutting-edgetechnologies. Many devices are assembled from several layers of plastic and glass. The

layers need to be aligned +/- 50um before bonding. The microfluidics fabrication lab atUCSB, located in Elings Hall, is building a tool to do this aligned bonding.

Goal: Design and build a chuck to hold one transparent layer of a multi-layermicrofluidic device for bonding. The chuck should:

Hold substrates of various dimensions up to 25mm x 75mm

Secure the substrate using vacuum, and release the vacuum after bonding

Incorporate a large opening so that the device below the layer in the chuck can be seen

Have a mechanism that allows easy and precise attachment and removal from the

bonding tool.

Notes:Students working on this project will work in the microfluidics lab developing and testing

their tool.


project.

Most labs building microfluidic devices find aligned bonding to be a significant

challenge. Students will be encouraged to publish their design.


16. MEMS Scribe and Break Tool Soh Lab (Faculty TBD)

Background: The Soh Lab often needs to cut rectangular pieces out of thin (0.5mm)glass sheets. The common techniques for cutting window glass do not work for sheetsthis thin, and the glass tends to break unevenly. As a result researchers must reserve timeon an expensive dicing saw to divide the sheets. They really would like a simple bench-top machine instead. High precision scribe and dice tools are available for thesemiconductor industry, and some of the technology incorporated there may be relevantto this low-cost machine.

Goal: Develop a low-cost tool for breaking thin sheets of glass along straight lines. Thetool should have the following features:

Support substrates up to 150mm square x 0.5mm thickBreak the glass on a straight lineAllow alignment of the device with the cutting line to +/- 0.1mm

mailto:[email protected]:[email protected]

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Commercial Opportunities: Many MEMS labs need this type of machine, and thedesign team is encouraged to develop their ideas into a commercial product.

Notes:

Contact Dave Bothman, [email protected] if you have questions about thisproject.


17. Digital Image Correlation System Calibrator Mount Zok/Fields

Digital image correlation (DIC) is a mechanical strain-mapping technique utilizing high-resolution stereo cameras to image a component and provide full, 3D displacements. Thesystem requires the component to be speckled with a black and white irregular patternwhich is then tracked by hardware and software. The digital image correlation techniqueis massively useful for visualizing deformations and strains on full-size structures downto millimeter-scale components.

The 3D digital image correlation system requires accurate calibration to achieve qualitydata. The system utilizes a precision target grid of known geometry which is imaged andcompared to a look-up table. This allows the software to compute all the imagingparameters (lens angles, focal lengths, working distance, etc.). Positioning of thecalibration target is paramount to good results.

This project will require designing and constructing a device which will allow formounting of the calibration target and provide manual, controlled motion of the target insix degrees-of-freedom (three translations and three rotations). The mount should becapable of supporting five sizes of targets as well as have the capability to interfacemechanically with a mechanical test machine.

mailto:[email protected]:[email protected]

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Student Organizations and Design Competitions

18. Rickshaw Transmission Design - EWB project (Bothman)

This project will be coordinated through the student chapter of EWB.

Engineers Without Borders USA is a non-profit organization that supports community-driven development programs worldwide through the design and implementation ofsustainable engineering projects, while fostering the development of internationallyresponsible engineering students. EWB-USA partners university students and workingprofessionals with underserved communities worldwide in need of technical assistance.

Background: Locally made single-speed rickshaws are the norm in Nepal, even though

the terrain is quite steep. The rickshaws are important for transportation of people andfreight.

Goal: The goal of the project would be to develop a reliable, cost-effective two (or more)speed transmission that could be fabricated in the Nepalese shops that build therickshaws. The transmission must be:

Reliable in the regular heavy-duty use

Buildable and repairable in Nepal

Inexpensive

Easy to use

There is a rich history of bicycle transmission technology that the team can use forinspiration in their design.

Notes:Contact Dave Bothman, [email protected] if you have questions

about this project.


www.ewb-usa.org

www.engineering.ucsb.edu/~ewb-ucsb

mailto:[email protected]://www.ewb-usa.org/mailto:[email protected]://www.ewb-usa.org/

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Independently Created Projects

19. Low Cost CNC Positioning Device for Science Outreach MRL (Faculty TBD)

This project is proposed by Frank Kinnaman and will be supported by MRL NSFoutreach funding.

This project aims to repurpose recent exciting advancements in the open-sourcedesktop computer numerical control machine (CNC) community towards use by highschool and junior high science teachers and students as low cost positioning devices andautosampler science projects. The project will be divided into two parts: the first beinginvestigating novel designs of the central weight-bearing motion system and the secondbeing the design and implementation of the mechanical interface of the machine with

various scientifically relevant attachments. Instead of the original intention of millingwith a rotary cutting tool the devices produced by this capstone project will preciselyposition, manipulate and control sensors, probes, usb microscopes, and handle fluids(syringes, electronic pipettes and small pumps). The central framework of the systemwill be closely modeled (with modifications) after existing projects using V-railaluminum extrusion and threaded rod stepper motor motion systems, mounts and endplates with special attention paid to possible cost-savings in materials.

Project mentor and MRL education outreach coordinator Frank Kinnaman has activepersonal interest in hobby CNC and professional interest in the applied k-12 science ascoordinator of the MRL Research Experience for Teachers program. On-hand physical

resources currently include a customized Project Shapeoko cnc machine (shapeokodescription link below), various water sensors (e.g. dissolved oxygen, salinity,temperature and other probes), and physically complete prototype arduinomicroprocessor systems including interface with appropriate sd card file storage systems,electronic pipette motor drivers and magnetic switching components. Personnelresources include undergraduate computer science major Aki Stankoski, interestedcolleague and expert arduino programmer Peter Sand of ManyLabs.com and localjunior high science teacher (Jesse Kasehagen, Santa Barbara Middle School) who willapply progress in this project to his science curriculum. Distribution of the results-to-date of this project may also be a topic of the annual MRL science teacher workshopheld in mid-march 2013.

Resources:project shapeokohttp://www.shapeoko.com/makerslide componentshttps://www.inventables.com/categories/innovative-materials/components/mechanical/makerslide

Jesse Kasehagen summer 2013 curriculum project (see pdf at bottom of page)http://mrlweb.mrl.ucsb.edu/education/ret-research-experience-teachers/jesse-kasehagen

(website revision underway, if broken use following link)

http://www.shapeoko.com/https://www.inventables.com/categories/innovative-materials/components/mechanical/makerslidehttp://mrlweb.mrl.ucsb.edu/education/ret-research-experience-teachers/jesse-kasehagenhttp://www.shapeoko.com/https://www.inventables.com/categories/innovative-materials/components/mechanical/makerslidehttp://mrlweb.mrl.ucsb.edu/education/ret-research-experience-teachers/jesse-kasehagen

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http://www.mrl.ucsb.edu/education/ret-research-experience-teachers/jesse-kasehagen

Further resources:

Video showing a breakthrough in sensor data organization MRL RET program summer2012:http://www.youtube.com/watch?v=E0XnEkgwYDU&list=UUKU6ThWB8e0rN9docm83VGw&index=1&feature=plcp

Shapeoko forum pictures better resembling the current shape of the modifications ofthe Shapeoko involved in this project.http://www.shapeoko.com/forum/viewtopic.php?f=11&t=326

Manylabs home page with examples of the possible data and physical computerinterfaces for the completed project (see pic slideshow)https://www.manylabs.com/

Microrax description pagehttp://www.microrax.com/

Project contact Frank Kinnaman: [email protected]

20. MEMS Fractionation Device Pennathur Lab (Faculty TBD)

This is a student generated independently created project. Prof. Sumita Pennathur hasoffered the use of her lab for test purposes and limited fabrication.

The proposed project is the design and development of a fractionation device that can sortparticles based on size. This device would be able to take a solution containingpolystyrene beads of sizes corresponding to various blood components and separate theminto distinct size groups.

Various methods of MEMS based blood fractionation have been attempted in recentyears. Most devices have used a micro-porous material or some other form of filtrationsystem. While these designs have been successful in generating separation, they havesuffered from low throughput rates and clogging of the filtering material, making themineffective for practical use. This proposed project would take a novel approach to blood

fractionation by using the basic properties of diffusion and size limitations to createseparation. By abandoning the idea of forcing blood through a filtering material, the goalof this project would be to create better separation while improving upon the problems oflow throughput and clogging common to current devices.

By using micro fabricated channels of sizes between 500 nanometers and 100micrometers, it would be possible to create a selectivity for different particle sizes in each

http://www.mrl.ucsb.edu/education/ret-research-experience-teachers/jesse-kasehagen%20http://www.youtube.com/watch?v=E0XnEkgwYDU&list=UUKU6ThWB8e0rN9docm83VGw&index=1&feature=plcphttp://www.youtube.com/watch?v=E0XnEkgwYDU&list=UUKU6ThWB8e0rN9docm83VGw&index=1&feature=plcphttp://www.shapeoko.com/forum/viewtopic.php?f=11&t=326https://www.manylabs.com/http://www.microrax.com/http://www.mrl.ucsb.edu/education/ret-research-experience-teachers/jesse-kasehagen%20http://www.youtube.com/watch?v=E0XnEkgwYDU&list=UUKU6ThWB8e0rN9docm83VGw&index=1&feature=plcphttp://www.youtube.com/watch?v=E0XnEkgwYDU&list=UUKU6ThWB8e0rN9docm83VGw&index=1&feature=plcphttp://www.shapeoko.com/forum/viewtopic.php?f=11&t=326https://www.manylabs.com/http://www.microrax.com/

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of the channels. A possible outflow with potential target molecules (if used with wholeblood) would be as follows:

Channel 1: ( > 20 um) Large particles and debrisChannel 2: (16-20 um) Circulating Tumor Cells

Channel 3: (10-15 um) Leukocytes (White Blood Cells)Channel 4: (8-10 um) Red Blood CellsChannel 5; (2-3 um) PlateletsChannel 6: ( 1 uL/minute2 Driving Pressure: 95% for particles greater than 10 um>70% for particles greater than 5 um>60% for particles greater than 1 um>50% for particles 1 um

4Minimum Filtering Volume: >5 mL5 Size of chip:

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