The three main requirements posed by the stakeholders include the following:

1.      A portable fabrication cell regulating humidity levels to 30% RH

2.      A temperature-controlled fixture for varying mold types

3.      Optimized processing parameters of MFE with support data

The IMPD team was able to deliver customized fabrication equipment and process design work instructions that would support research activities into the future state. The IMPD team developed conceptual designs for a glovebox designated 1.1 to house the AB100 injection molding equipment. In addition, a desiccant drying system was integrated to supply treated facility air into the control environment with reduced RH levels and low particulate counts. It was determined that to meet project timeline expectations that the fabrication of 1.1 would be sourced to a 3rd party manufacturer. The decision to outsource fabrication was supported by a supplied certificate of compliance which guaranteed the equipment’s functionality. The portability of 1.1 was achieved through the acquisition of a prefabricated cart to which the glovebox and desiccant dryer were fixed. Subsequent testing revealed that levels of 14% RH were achieved, exceeding stakeholder requirements.

The temperature control fixture designated 1.2 featured customized molding solutions for the AB100 equipment. The IMPD design engineers employed engineering principles of fluid dynamics, heat transfer, and material science to effectively design an insert molding fixture. The fixture features 2 heating cartridges wired in parallel to a voltage controller that receives active feedback from a standard thermocouple to regulate heating cycles. In addition, the fixture features ported channeling for liquid cooling upgrades. The IMPD team achieved stable temperature control at 180°C, allowing for optimized cavity pack-out. The interchangeable insert cavity allows for quick processing rates, and low-cost cavity alterations increase net productivity.

For deliverable 3, a design of experiments was developed to actively fabricate MFE coupons. A subsequent work instruction was developed which outlined the processing parameters required for fabrication. Next, each technician performed a series of experimentation featuring 5 trials. These results were documented and evaluated to supply the stakeholder with optimum processing parameters based upon compositions that range from 100%-PET to 70% -PET + 30%-LiTFSI compositions. It was found that the process design was capable and repeatable throughout all compositions.

In conclusion, the IMPD team fulfilled or exceeded the criteria set forth by the stakeholders. In the future state, it has been recommended to the stakeholders that a preventative maintenance schedule should be developed to support the process design supplied. In addition, the exchange of material compositions should be evaluated for use within this custom molding solution to ensure effectiveness.

Fluid Metering Inc has tasked our team with designing and manufacturing a quick connection for the calibration of their OEM Sub-1 Duplex Pump. The goal is to provide a timed connection and disconnection of less than 1 second, which is 5 seconds less than the current calibration design. It is crucial to maintain the pump’s extreme precision and efficiency at dispensing the desired flow rate while achieving this.

Initially, our group conducted thorough background research on the supplied pump and various methods for quick connections that are currently available. We then brainstormed design concepts and evaluated each one based on weighted CTQ drivers to determine the best solution while adhering to safety standards. Our winning design utilizes two toggle clamps to apply a force on the two outlet pump heads on the top of the pump, creating a reaction force for the two inlet pump heads on the bottom of the pump.

To ensure the design’s efficiency, we conducted control and leakage tests. After testing many different methods of preventing leaks, we discovered that using a barbed fitting with a rubber stopper attached to the end of the toggle clamp provided similar results to the control while also speeding up the connection and disconnection time.

In summary, our team designed and manufactured a quick connection that achieves a timed connection and disconnection of less than 1 second while maintaining the OEM Sub-1 Duplex Pump’s extreme precision and efficiency. The use of two toggle clamps and a barbed fitting with a rubber stopper resulted in a successful design that met the desired CTQ drivers and safety standards.

The objective of the MADWEC 4.0 mechanical team was to optimize and redesign the PTO system, which utilizes the oscillatory motion of the waves and a reel system to spin a shaft that drives a generator to create power output. The previous year’s PTO system had a low power output and efficiency, so the team needed to update the system to increase power output and optimize efficiency by characterizing the losses in the system and separating mechanical and electrical losses. To achieve this, the entire system was redesigned into a bench-top test setup utilizing a rail system. Each component was coupled together with shaft couplings to create subassemblies that can be easily removed or shifted along the rails to allow for the implementation of new components. The system is now modular, and sensors, including a reaction torque sensor, a rotary encoder, a load cell, and multiple current sensors, were implemented throughout the system to characterize mechanical and electrical losses. The final major change to the system was the use of a single low RPM generator instead of six small high RPM generators. This allowed the system to reach the nominal RPM of the generator, ultimately increasing power output.

This project aims to design an underwater holographic imaging system to precisely detect marine microplastics. The project is sponsored by Dr. Hangjian Ling, an assistant professor at UMass Dartmouth. The team has developed a system that uses three-dimensional (3D) imaging based on digital holography. It employs a camera, laser, and microscope objective to detect microplastics. The team spent several weeks researching optical imaging, microplastics, and digital holography to design the system correctly.

To ensure the system can accurately image marine microplastics while withstanding the pressure underwater, the team purchased the necessary optical parts and manufactured different components for the housing. They completed calculations and testing to find the focal length and confirm no leakage occurs while the housing is underwater. All optics are concentric with each other, guaranteeing that the microplastics will be accurately imaged. The resulting images from the system can be used to further research the link between microplastics and the health issues caused by consuming them.

The goal of this project is to create a system that provides safe, consistent, fast, and cost-effective results for companies with small batches of parts that need to be anodized. Ideally, the outcome will fill the gap found in the market by the sponsor, Alex LeGendre, with a more desirable option. The team at the University of Massachusetts Dartmouth was given the task of creating a prototype system that fills the gap described above. The project began with research to understand the anodizing process and the current market situation. From there, Environmental Health and Safety (EHS) documentation was created to ensure that the team was fully informed about the chemicals being used. Through many rounds of brainstorming, designing, and redesigning, the final prototype design was arrived at and manufactured. This final prototype will hopefully lay the groundwork for a final product that will fill the gap in the anodization space.