ME 189/197 2012-13 Capstone Design Project List (rev … with an interest in mechanisms and...

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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 Grumman Aerospace Systems - Space Systems Division located in Redondo Beach, California. Northrop Grumman Corporation is a $30 billion global defense and technology company whose 120,000 employees provide innovative systems, products, and solutions in information and services, electronics, aerospace and shipbuilding to government and commercial customers worldwide. Northrop Grumman is a premier developer, integrator, producer and supporter of manned and unmanned aircraft, spacecraft, high-energy laser systems, microelectronics and other systems and subsystems critical to maintaining the nation’s security and leadership in science 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; missile defense; earth observation; space science; and space exploration. Northrop Grumman Space Technology develops a broad range of systems at the leading edge of space, defense and electronics technology. Building on a heritage of innovation, we create sophisticated products that contribute significantly to the nation's security and leadership in science and technology. Project Description: Mechanisms and deployables are an important aspect of any spacecraft design due to the likely 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. The students will demonstrate a mechanism design that will deploy a parabolic antennae from a CubeSat. The design of the mechanism and antennae must meet stringent stowage requirements, launch load requirements, and strict deployed characteristics to ensure mission success. Typical driving parameters include size, mass, thermal environments, launch loads, and reliability. Verification of the design will also require students to develop a test fixture to demonstrate their concept. The company requires US citizenship for all site visits and a Confidential Disclosure Agreement. 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 periodic teleconferences. Website: www.as.northropgrumman.com/index.html ME 189/197 Page 1 of 27 Design Projects

Transcript of ME 189/197 2012-13 Capstone Design Project List (rev … with an interest in mechanisms and...

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 Grumman Aerospace Systems - Space Systems Division located in Redondo Beach, California.Northrop Grumman Corporation is a $30 billion global defense and technology company whose 120,000 employees provide innovative systems, products, and solutions in information and services, electronics, aerospace and shipbuilding to government and commercial customers worldwide. Northrop Grumman is a premier developer, integrator, producer and supporter of manned and unmanned aircraft, spacecraft, high-energy laser systems, microelectronics and other systems and subsystems critical to maintaining the nation’s security and leadership in science 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; missile defense; earth observation; space science; and space exploration. Northrop Grumman Space Technology develops a broad range of systems at the leading edge of space, defense and electronics technology. Building on a heritage of innovation, we create sophisticated products that contribute significantly to the nation's security and leadership in science and technology.

Project Description:Mechanisms and deployables are an important aspect of any spacecraft design due to the likely 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. The students will demonstrate a mechanism design that will deploy a parabolic antennae from a CubeSat. The design of the mechanism and antennae must meet stringent stowage requirements, launch load requirements, and strict deployed characteristics to ensure mission success. Typical driving parameters include size, mass, thermal environments, launch loads, and reliability. Verification of the design will also require students to develop a test fixture to demonstrate their concept.The company requires US citizenship for all site visits and a Confidential Disclosure Agreement.

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 periodic teleconferences.

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

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2. Reusable Release Actuator – ATK (Faculty TBD)

This project is in cooperation and partnership under a gift with ATK Space Systems located in Goleta. ATK Space Systems in Goleta is a leading producer of deployable space systems. Products include deployable Booms, Solar Arrays, and Stable Structures and Antennas. With over 70 successful Spaceflight Missions, detailed assembly processes and rigorous testing in simulated space environments are key elements in maintaining our 100% mission success. Recent programs include the NASA NuSTAR Boom and Solar Arrays, NASA Mars Phoenix Lander Solar Arrays and Boom Camera Structure as well as GPS Solar Arrays.

Hold down and Release Mechanisms are standard components for spacecraft in order to achieve mission related critical functions. Their main functions are to secure during launch and to release once in orbit, or during descent to/on planetary surface, movable payload items, deployable appendages and separable mission elements. They can also be used in order to achieve timely synchronization for the deployment and/or ejection of specific appendages or separable mission elements.

As shown in Figures 1 and 2, a common release mechanism design know as a “split-spool device” includes two spool halves each having external surfaces and a generally flat internal surface, a unitary and integral internal member made of an electrically conductive material and having a link-wire portion and two electrical terminal portions, and an external wrap-wire wound around the two spool halves and having a connecting end connected to the link-wire portion of the unitary and integral internal member such that the wrap-wire tightly binds the two spool halves together to form a spool for retaining an external structural member. When an electrical current of a sufficient magnitude is applied through the electrical terminal portions of the unitary and integral internal member, the link-wire portion of the unitary and integral internal member will be heated, which reduces its tensile strength to the point of rupture.

F = 112-450 lb

Nominal state: wound spring holds split nut together

Fired position: spring unwinds to a larger diameter and split nut is forced apart by chamfered bolt head

Bolt is free to leave device

F = 20 lb (main ejection spring + latchtrain bias springs)

F = 112-450 lb

3-5 amperes

F = 112-450 lb

Nominal state: wound spring holds split nut together

Fired position: spring unwinds to a larger diameter and split nut is forced apart by chamfered bolt head

Bolt is free to leave device

F = 20 lb (main ejection spring + latchtrain bias springs)

F = 112-450 lb

3-5 amperes

Figure 1. Split Spool release device typical operation.

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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 NEA devices for ground test – that does not need to be sent back to the factory to be re-set. The style and type of release (manual-mechanical or electrical activation) for the reusable device 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 determine changes/testing needed for a fully qualified space rated mechanism.

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Implementation of this device is expected to greatly simplify testing which involves release mechanisms. Consequently, this is a high visibility project for ATK Goleta Operations Management. Participants of this project will receive exposure to a variety of space 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 <http://www.atk.com/>

3. Camera Drive System – FLIR (Faculty TBD)

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

FLIR Systems, Inc. is the global leader in Infrared cameras, night vision and thermal imaging systems. Our products play pivotal roles in a wide range of industrial, commercial and government activities in more than 60 countries. Pioneers in the commercial infrared camera industry, the Company has been supplying thermography and night vision equipment to science, industry, law enforcement and the military for over 30 years. From predictive maintenance, condition monitoring, non-destructive testing, R&D, medical science, temperature measurement and thermal testing to law enforcement, surveillance, security and manufacturing process control, FLIR offers the widest 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 final system 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 a system using this camera because it lacks a small motion control system.

• Opportunity– Design a cost effective motion control pan-tilt system for one of the

smallest thermal cameras in the world.– This critical mechanical component will allow for the construction of one

of the smallest commercially available pan-tilt camera systems by enabling FLIR to develop only the electrical and software control components.

Project Scope:Design and demonstrate a prototype of a system that will both pan and tilt while housing a 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 a demanding and technically challenging project.

Student Requirements:• Solidworks knowledge• Some understanding of electrical systems and control• Thermal and dynamics expertise

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: 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 imaging devices for applications in the x-ray, visible, infrared, terahertz and millimeter wave regions of the electromagnetic spectrum. RVS is well regarded as an intellectual and technological development leader. A complex of buildings that house development laboratories, offices, and manufacturing facilities provide RVS with world class capability for development and fabrication of top of the line sensing products. This RVS site, located in Goleta, California, employs approximately 1,000 people with functional organizations engaged in research and development, design engineering, and manufacturing.

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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RVS’s reputation as a premier world class provider of infrared sensors is in part due to the unique crystallographic material that is developed, grown and processed on site. This highly specialized material varies in shape from squares to rectangles and also comes in multiple sizes. Assembly processing of infrared detectors at RVS includes applying anti reflection (AR) coating. The purpose of this project is to explore and develop new low cost methods for fixturing detectors of various sizes and materials while the AR coating is applied. The AR coating process is critical to the product, well established, and must be maintained. Improved fixturing and handling is required to improve cost and manufacturing cycle time efficiencies.

Project Scope: While working with industry leading engineers, students can expect to gain a solid concept of basic semiconductor properties, tooling and manufacturing techniques. That understanding will be critical to the design and fabrication of tooling capable of AR coating next generation infrared detectors. Tooling will need to be class 5 cleanroom compatible and allow for easy removal and precision remounting of various size and shape IR sensor chips. AR coating is applied to a specific region on the detector surface to close tolerances via a thin film deposition vacuum chamber. Some key critical considerations for the tooling will be: must be vacuum compatible; must not particulate; must be electrically conductive; must be ergonomic. Fixturing may be fabricated using conventional machining, direct digital manufacturing, laser machining, chemical machining, etc.

Students interested in Manufacturing Engineering, Process Engineering, Industrial Engineering and the semi-conductor industry should find this project challenging and reward. The demands for fixturing to improve handling and production efficiencies while maintaining precision and tolerance requirements should prove challenging.

Student Requirements:US citizenship or permanent residentProprietary Information Agreement and Invention Agreement

Ideal Student Qualifications: An ideal candidate will be one who is familiar with mechanical design programs, willing explore micro-electronic processing equipment in a cleanroom environment, to be hands on, ready to learn and capable of developing innovative solutions. Students will be expected to interact with Raytheon engineering on an ongoing basis and visit the site regularly. Familiarity with a cleanroom environment is helpful but not necessary.

Website: http://www.raytheon.com/businesses/ncs/rvs/index.html

5. Low Cost Fixed Pressure Valve – Medtronic Neurosurgery ( Laguette )

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

Medtronic Neurosurgery (MNS) is a local medical device company that is a leader in the field of neurosurgical implants and devices. Medtronic is the global leader in medical technology, alleviating pain, restoring health and extending life for millions of people around the world. MNS is a world leader in the design and manufacture of implants and devices 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 the flow of the fluid that surrounds the brain. This fluid is called the cerebrospinal fluid, or CSF. It surrounds the brain and spinal cord, and helps cushion the brain. CSF normally moves through the brain and the spinal cord, and is soaked into the bloodstream. CSF levels in the brain can rise if:

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The flow of CSF is blocked

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It does not get absorbed into the blood properly

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Your brain makes too much of it Too much CSF puts puts pressure on the brain. This pushes the brain up against the skull and damage brain tissue.Hydrocephalus may begin while the baby is growing in the womb. It is common in babies who have a myelomeningocele, a birth defect in which the spinal column does not close properly. Long-term implants known as Shunts have been used to treat hydrocephalus for more than 50 years. The devices allow excess cerebrospinal fluid to drain to another area of the body. A Shunt usually consists of two catheters and a one-way valve. The valve regulates the amount, flow direction, and pressure of cerebrospinal fluid out of the brain’s ventricles. 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:

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

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

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A lumboperitoneal shunt moves fluid from the lower back to the abdominal cavityA Fixed Pressure Valve is designed to regulate the flow rate of cerebrospinal fluid based on 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 done by Dr. Benjamin C. Warf compares different shunt systems and highlighting the role of low cost shunt systems in most of the developing countries. This study has been published in Journal of Neurosurgery: Pediatrics May 2005 issue.Project Description: The purpose of this project is to design a low cost fixed pressure valve that may be incorporated 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. The design 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 allow for different fixed pressure values, e.g. low, medium and high pressure versions of the same valve. The valve should be fabricated of acceptable implant materials that may be incorporated into a shunt implant system. It is anticipated that special attention regarding assembly and test methods to address low cost manufacture must be included in the design.

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

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

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 Silicone Corporation. Applied Silicone Corporation, based in Santa Paula, a leading producer of silicone, supplies raw material and technical and regulatory support to manufacturers of FDA registered 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 to address issues with handling silicone materials. Existing suck-back technology does not provide an adequate break in the product stream when preparing to fill the next syringe leading to inaccuracies in metering and inconsistent dispensing. Hence, this current syringe 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, computer programming, and quality control.

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Engineering Deliverables:

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

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

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

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

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The final system appearance should reflect its commercial viability.Student Requirements:

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

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

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A signed Non‐disclosure agreement (NDA) is also required.

Students interested in designing and developing a production-ready system or equipment will find this project to be demanding and challenging. Students interested in Process Engineering and Industrial Engineering should find this project challenging and rewarding.

Ideal candidates will be skilled in mechanical design using SolidWorks and in executing the 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 be required to sign a Non-Disclosure Agreement and any successful design resulting from this 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 a global presence. Its core businesses are research and development and the manufacturing of 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 blindness worldwide. Treatment consists of a routine surgical intervention that is successfully performed millions of times each year. During refractive lens exchange surgery, the crystalline 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 development offer the promise toward restoration of accommodation. Development of accommodative IOLs requires in-vitro models and testing systems to characterize changes in mechanical and 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 optical properties of various intraocular lenses. The system must be able to perform compression force, contact angle, and other testing of IOLs in-line with relevant ISO standards. AVS currently 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 for holding various size lenses, in-line with relevant ISO standards.

Teams should expect to use SolidWorks for part and assembly drawings. Characterization of 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 the mechanism 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 find this 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 better surgical solutions for spine patients. Today, NuVasive continues to revolutionize minimally disruptive surgical solutions, allowing surgeons to treat spine conditions while minimizing the surgical trauma experienced. NuVasive procedures have consistently garnered 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. NuVasive’s business is centered around a unique and nominal spine surgical technique that revolutionized the way in which surgeons address and tackle these problems. As opposed to a typical anterior (front) or posterior (back) surgical approach, NuVasive became the pioneers of a patented, lateral (side) surgical procedure. This procedure, known as XLIF (Extreme Lateral Interbody Fusion), permits safe and easy access to the lateral aspect of the spine while preventing excess blood loss and limiting the morbidity of the surgery (resulting in quicker patient recovery). A common problem in surgery is coming in contact and harming nerves en route to the spine. Therefore, a key compliment to the XLIF procedure is a nerve detection system. This device works with the XLIF instrumentation, reading electrical signals from the nerves that send audible feedback to the surgeon. The audible feedback allows the surgeon 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 and lumbar spine as well as the previously mentioned nerve detection system. NuVasive has more 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 (anterior cervical 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 via Google “ACDF surgery” searches.

DESIGN BACKGROUND: To help achieve fusion between two vertebrae, a cervical plate 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 thread forms 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. These manual drivers enable precise control of location and depth of the bone screw but can be tedious 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 a list 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 in order to provide a viable design proposal. ASTM standards and FDA regulations should also be considered when working with medical instruments and devices.

Prototype/Proof of concept expectations:

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Students must provide complete CAD package – including drawings and models.

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Students may provide CAD models in .STP format to have NuVasive SLA 3D print proof of concept.

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Students must prototype individual mechanisms – as one full assembly or as separate sub-assemblies in order to perform testing.

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

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 Design in Biomedical Engineering Education

This grant will directly support undergraduate team-based biomedical design projects created through UCSB’s Department of Mechanical Engineering (ME), Department of Electrical and Computer Engineering (ECE), and the Center for Bioengineering (CBE) with the Santa Barbara Cottage Health System (SBCHS), a provider of acute hospital care to the greater Santa Barbara region. Critical elements of this program are that each project will have a direct connection to immediate, local clinical needs, and that each project requires that the students merge their mechanical, electrical and biomedical engineering expertise with the medical insights of our clinical mentors. This will provide students with a unique learning experience that mimics the integrated approaches of engineers working in the biomedical industry. Importantly, these projects will provide the student and team to be immersed in the clinical environment, developing an understanding and appreciation of therapies, treatments, health care delivery, and quality of life concerns. Through this award, the biomedical components of existing Capstone courses will be expanded, to include clinically-relevant biomedical design projects jointly created by our students and by university and hospital faculty and staff. Under the joint supervision of a UCSB faculty advisor and SBCHS mentor, students will work in multidisciplinary teams of three to five (consisting of undergraduate majors in ME and ECE, as well as Bioengineering concentrators in our College of Creative Studies) to tackle a significant design and build project from concept through project completion and device 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. Prolonged stays 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 walking program could have a beneficial effect on all of these factors. An early mobility program encompasses progressive mobilization and walking, with progression based on a patient’s functional capability. Mobilization and the ability of an ICU patient to walk is also limited by the required equipment needed to provide care for the patient including monitoring equipment, infusion pumps, oxygen, suction, chest tubes, and catheters. It is desired to design and develop a functional prototype of a cart that will allow the use of all necessary equipment while connected to an ICU patient during mobility and walking. This Mobility Cart for ICU Patients should enable patients to be proactive in their recovery.

It is desired that a functional prototype will be developed for laboratory testing and evaluation 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 Care Medicine 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 Cottage Hospital in August, 2004. He is Board Certified in Internal Medicine, Critical Care, and Pulmonary Medicine.

The student team may be comprised of ME students as well as interested Bioengineering concentrators 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 Design in Biomedical Engineering Education

This grant will directly support undergraduate team-based biomedical design projects created through UCSB’s Department of Mechanical Engineering (ME), Department of Electrical and Computer Engineering (ECE), and the Center for Bioengineering (CBE) with the Santa Barbara Cottage Health System (SBCHS), a provider of acute hospital care to the greater Santa Barbara region. Critical elements of this program are that each project will have a direct connection to immediate, local clinical needs, and that each project requires that the students merge their mechanical, electrical and biomedical engineering expertise with the medical insights of our clinical mentors. This will provide students with a unique learning experience that mimics the integrated approaches of engineers working in the biomedical industry. Importantly, these projects will provide the student and team to be immersed in the clinical environment, developing an understanding and appreciation of therapies, treatments, health care delivery, and quality of life concerns. Through this award, the biomedical components of existing Capstone courses will be expanded, to include clinically-relevant biomedical design projects jointly created by our students and by university and hospital faculty and staff. Under the joint supervision of a UCSB faculty advisor and SBCHS mentor, students will work in multidisciplinary teams of three to five (consisting of undergraduate majors in ME and ECE, as well as Bioengineering concentrators in our College of Creative Studies) to tackle a significant design and build project from concept through project completion and device 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 systems have alarm systems that are activated based upon clinical needs. These alarm systems are required for appropriate nursing care and health care delivery. This creates a noisy environment for the patient in the room. It is desired to improve the noise levels in patient rooms 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 and evaluation only. The system is not intended for immediate patient use. It is envisioned that this proof-of-concept prototype will be a simple infusion system with well-defined controllable parameters linked with an alarm system. The alarm system will be wirelessly linked to a personal hand-held device (.i.e. Android Smartphone).

This project will be clinically mentored by Jeff Fried, MD, Director, Critical Care Medicine 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 Cottage Hospital in August, 2004. He is Board Certified in Internal Medicine, Critical Care, and Pulmonary Medicine.

The student team may be comprised of ECE students, ME students as well as interested Bioengineering concentrators in the College of Creative Studies. Due to the expected complexities of this project regarding wireless connectivity, this project will require ECE students 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 of the Marine Science Institute and Earth Science Dept.

Background and project purpose

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

Description, pics and video:http://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 including the Santa Monica Basin (~1000m depth), Santa Barbara Mid Channel Trend (~200m depth) and Gulf of Mexico. Due to the high pressures and low temperatures methane can also take a solid “methane hydrate form” at these depths. This research at deeper sites is conducted on biennial research cruises using the deep sea vehicles Alvin or Jason aboard the Atlantis, the nation’s premier oceanographic research vessel. The next cruise is scheduled 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, a model developed and on semi-permanent loan to us by researchers at USC. Although these samplers have served successfully for 3 major research cruises they have some inherent weak points and the overall performance of these gas samplers has markedly deteriorated necessitating a redesign. Instead of simply refabricating the same sampler with more robust parts we propose changing the fundamental sampling method to allow for better isolation of the sample from contamination. The completed device will also be modified as part of this project to mate with an existing methane hydrate flux measuring device for the deeper (>700m) settings.

It is very likely that at least a subset of students involved in this project will be invited along for the entirety or a portion of the 2.5 week “SEEPS 2013” research cruise in october 2013 aboard the Atlantis (exact dates TBA), with preference for students who have 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 the proposed 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

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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 to cosmology. The application here requires extremely lightweight and precise optics that can be replicated which requires the use of a negative mold. It can cost hundreds of thousands of dollars to machine a high precision mold for optical elements. For cases where multiple unique molds are required for production, the cost can become prohibitive. Cost can be reduced significantly by replacing the expensive rigid molds with 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 needed shape using linear actuators. The deformed plate can then be used as a mold surface for constructing carbon-fiber-reinforced polymer (CRFP) panels. Hundreds of uniquely shaped CRFP panels are required to build large telescope mirrors. Theoretically, a single MMS 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 and improvements of the MMS with electronically activated linear actuators that are controlled by Labview with a variety of plate materials. Project outcomes would include the selection of an optimum plate membrane material, the identification of predictive deformation metrics within defined accuracy limits, and demonstrated use of the MMS in producing unique CRFP test samples.

Students interested in working in a challenging and exciting research environment will find this project of interest. Significant technical challenges are expected in FEA modeling and testing of membranes under stressed edge conditions, metrology of surfaces and use of metrology test systems, algorithms to optimize surfaces and replication techniques using CFRP on molds.

Independent fund raising efforts including an URCA grant will be necessary to support project efforts.13. Vacuum Pump Acoustic and Vibration Enclosure – Turner Lab (Faculty TBD)Background: The small vacuum pumps that are ubiquitous in research labs create a disturbing amount of noise, as well as vibration that is carried through the vacuum lines to sensitive experiments.

Goal: Design and build a prototype enclosure that:

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Reduces the noise level to an acceptable level

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

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Is easily moved around the lab

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

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An automatic over-temperature shut off.

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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 the design team is encouraged to develop their ideas into a commercial product.

Notes:

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The team will be given a vacuum pump that is typical of those needing enclosures to work with during the school year.

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

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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-based interferometers that measure the displacement and velocity of vibrating microstructures. The devices are placed in a variety of sample holders that allow researchers to control gas mixture, pressure and temperature of the environment around them. Because the microscope objectives have a small depth of field, it is important that the sample plane be parallel 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:

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Allow fine adjustments of pitch, roll and height of a platform approximately 12” x 12”.

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Support a 10kg platform

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

Notes:

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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.

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

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Funds to support this project are available.

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

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Background: Microfluidics is a technology involving the fluid mechanics with channels having micron-scale dimensions. Microfluidic devices are used in energy, chemistry, physics, biology and medical research. They are incorporated in many cutting-edge technologies. Many devices are assembled from several layers of plastic and glass. The layers need to be aligned +/- 50um before bonding. The microfluidics fabrication lab at UCSB, 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-layer microfluidic device for bonding. The chuck should:

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

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

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

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

Notes:

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Students working on this project will work in the microfluidics lab developing and testing their tool.

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

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Most labs building microfluidic devices find aligned bonding to be a significant challenge. Students will be encouraged to publish their design.

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Funds to support this project are available.

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 sheets this thin, and the glass tends to break unevenly. As a result researchers must reserve time on 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 the semiconductor industry, and some of the technology incorporated there may be relevant to this low-cost machine.

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

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Support substrates up to 150mm square x 0.5mm thick

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Break the glass on a straight line

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Allow alignment of the device with the cutting line to +/- 0.1mm

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

Notes:

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

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Funds to support this project are available.

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. The system requires the component to be “speckled” with a black and white irregular pattern which is then tracked by hardware and software. The digital image correlation technique is massively useful for visualizing deformations and strains on full-size structures down to millimeter-scale components.

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

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

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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 of sustainable engineering projects, while fostering the development of internationally responsible engineering students. EWB-USA partners university students and working professionals 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 and freight.

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 the rickshaws. The transmission must be:

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Reliable in the regular heavy-duty use

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Buildable and repairable in Nepal

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Inexpensive

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Easy to use

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

Notes:

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

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Funds to support this project are available.

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www.ewb-usa.org

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

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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 NSF outreach funding.

This project aims to repurpose recent exciting advancements in the “open-source” desktop computer numerical control machine (CNC) community towards use by high school and junior high science teachers and students as low cost positioning devices and “autosampler” science projects. The project will be divided into two parts: the first being investigating novel designs of the central weight-bearing motion system and the second being the design and implementation of the mechanical interface of the machine with various scientifically relevant attachments. Instead of the original intention of milling with a rotary cutting tool the devices produced by this capstone project will precisely position, manipulate and control sensors, probes, usb microscopes, and handle fluids (syringes, electronic pipettes and small pumps). The central framework of the system will be closely modeled (with modifications) after existing projects using V-rail aluminum extrusion and threaded rod stepper motor motion systems, mounts and end plates with special attention paid to possible cost-savings in materials.

Project mentor and MRL education outreach coordinator Frank Kinnaman has active personal interest in hobby CNC and professional interest in the applied k-12 science as coordinator of the MRL Research Experience for Teachers program. On-hand physical resources currently include a customized “Project Shapeoko” cnc machine (shapeoko description link below), various water sensors (e.g. dissolved oxygen, salinity, temperature and other probes), and physically complete prototype arduino microprocessor systems including interface with appropriate sd card file storage systems, electronic pipette motor drivers and magnetic switching components. Personnel resources include undergraduate computer science major Aki Stankoski, interested colleague and expert arduino programmer Peter Sand of “ManyLabs.com” and local junior high science teacher (Jesse Kasehagen, Santa Barbara Middle School) who will apply 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 workshop held in mid-march 2013.

Resources:“project shapeoko”http://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)

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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 summer 2012:http://www.youtube.com/watch?v=E0XnEkgwYDU&list=UUKU6ThWB8e0rN9docm83VGw&index=1&feature=plcp

Shapeoko “forum” pictures better resembling the current shape of the modifications of the 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 computer interfaces 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 has offered 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 sort particles based on size. This device would be able to take a solution containing polystyrene beads of sizes corresponding to various blood components and separate them into distinct size groups.

Various methods of MEMS based blood fractionation have been attempted in recent years. Most devices have used a micro-porous material or some other form of filtration system. While these designs have been successful in generating separation, they have suffered from low throughput rates and clogging of the filtering material, making them ineffective 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 create separation. By abandoning the idea of forcing blood through a filtering material, the goal of this project would be to create better separation while improving upon the problems of low throughput and clogging common to current devices.

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

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of the channels. A possible outflow with potential target molecules (if used with whole blood) 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: ( <.5 um) Blood Plasma(Particle Sizes obtained from [1]

The fabrication of a working prototype of the device is desired. It is also probable that early large-scale prototypes would be made using the 3-D printer in the design lab. It is desired to build a prototype of a device capable of sorting particles of sizes comparable to various blood components.

Additional research will need to identify key parameters. A scan of several current MEMS filtration devices has led to the following initial design parameters:

1 Throughput Rate: >1 uL/minute 2 Driving Pressure: <10 psi3 Filtering Efficiency (% of particles successfully separated):

>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

4 Minimum Filtering Volume: >5 mL5 Size of chip: <13 square inches

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

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