After the development of additive manufacturing technology in the 1980s, it has found use in many applications like aerospace, automotive, marine, machinery, consumer and electronic applications. In recent time, few researchers have worked on the applications of additive manufacturing for heat transfer and fluidic devices. As the world has seen a drastic increase in population in last decades which have put stress on already scarce energy resources, optimization of energy devices which include energy storing devices, heat transfer devices, energy capturing devices etc. is need for the hour. Design of energy devices is often constrained by manufacturing constraints thus current design of energy devices is not an optimized one. In this research we want to conceptualize, design and manufacture optimized heat transfer and fluidic devices by exploiting the advantages provided by additive manufacturing. We want to benefit from the fact that very intricate geometry and desired surface finish can be obtained by using additive manufacturing. Additionally, we want to compare the efficacy of our designed device with conventional devices. Work on usage of Additive manufacturing for increasing efficiency of heat transfer devices can be found in the literature. We want to extend this approach to other heat transfer devices especially tubes with internal flow. By optimizing the design of energy systems we hope to solve current energy shortage and help conserve energy for future generation.We will also extend the application of additive manufacturing technology to fabricate "device for uniform flow distribution".

Proximal humerus fractures are the third most common fractures in the over-65 patient population and their stable fixation remains a key challenge in orthopaedic and trauma surgery. While Open Reduction Internal Fixation by plate has become a well-known treatment modality in the last few decades, clinical studies associate high complication rate with its use. The overall aim of this project was to create a computer-aided design framework for proximal humerus plates using a validated subject-specific humerus-plate finite element model. The framework consisted of three stages: (1) reverse engineering of bone and plate geometry, (2) creation and validation of a finite element model simulating the in vitro testing of the bone-implant construct and (3) parametric optimisation study of implant design using this model. In vitro biomechanical tests were conducted to not only compare the mechanical performance of three key commercially available proximal humerus plates (S3-, Fx- and PHILOS plate) but also the effect of different screw zones. Sixty-five humeri specimens with two-part surgical neck fractures were treated and grouped based on their different screw configurations. Extension, flexion, varus and valgus bending were applied in the cantilever fashion in the elastic tests whereas only varus bending was applied in the plastic tests. The load required to apply 5 mm displacement was measured to determine bone-plate construct stiffness. The S3 plate yielded the stiffest constructs and while the removal of the inferomedial support had the most impact on varus bending stiffness, type of medial support was important: inferomedial screws in the Fx plate achieved higher bending stiffness than blade insertion. Stability of constructs treated with the plate was an interplay of factors such as the plate’s and screws' number, orientation and position. Next, a subject-specific finite element model of the humerus-plate construct was successfully developed that simulated the stiffest of the constructs from the in vitro varus bending tests conducted in this project. The model was validated against the in vitro results. The validated model was then used to perform a parametric optimisation study where the combination of design parameters (height and divergence angle of S3 plate’s inferomedial screws) was determined that achieved optimum bone-plate construct stability (minimum fracture gap change). Out of the 538 designs tested, the optimum design (16o divergence angle and 33o height angle) yielded the lowest fracture gap change (0.156 mm) which was 4.686% lower than the standard finite element model while achieving 5.707% higher varus bending load (54.753 N). The validated model was also used to investigate the issue of using smooth pegs and threaded screws. Twenty-six models with different percentages of screw threading were run to compare their bone-plate construct stiffness. While threading the smooth pegs was found to increase the varus bending stiffness by up to 4.546%, it did not affect all screws equally. Finally, the successful completion of the optimisation study of screw orientation and the clinical investigation promises the implementation of the computational framework for a range of future multi-objective optimisation studies of multiple design parameters especially for the design of implants for other parts of the human body and also for investigations into other clinically relevant questions.

Soft robotic systems are becoming increasingly popular as they are generally safer, lighter, and easier to manufacture than their more rigid, traditional counterparts. These advantages allow an increased sense of freedom in both the design and operation of these platforms. In this work, we seek methods of leveraging this freedom to both design and plan motions for two different serial-chain, pneumatically actuated manipulators developed by Pneubotics, a small startup company based in San Francisco. In doing so, we focus primarily on two related endeavors: (1) the optimal kinematic design of these and other similar robots (i.e., choosing link lengths, base positioning, etc.), and (2) the planning of smooth paths in joint space that enable these robots to perform useful tasks. Our method of design optimization employs a genetic algorithm in combination with maximin multi-objective optimization techniques to efficiently generate a diverse set of Pareto optimal designs. This set represents the optimal region of the design space and highlights inherent tradeoffs that designers must make when choosing a particular set of design parameters for manufacture. In our work, we have chosen to optimize inflatable robots to be both dexterous, and to be able to support loads near the ground with limited deflection. We have also applied our framework to optimize a plastic manipulator to perform painting motions. In our approach to motion planning we simultaneously optimize the base position and joint motions of a robot in order to enable its end effector to follow a smooth desired trajectory. While this method of path planning generalizes to any kind of robot, we envision it to be especially applicable to soft robots and other mobile robots that can be quickly and easily repositioned to perform tasks in varying environments. Our method of path planning works by moving a set of virtual robot arms (each representing a single configuration in a sequence) branching from a common base, to a number of assigned target poses associated with a task. Additional goals and hard constraints (including joint limits) are naturally incorporated. The optimization problem at the core of this method is a quadratic program, allowing constrained high-dimensional problems to be solved in very little time. We demonstrate our method by planning and performing painting motion on two different systems. We also demonstrate in simulation how our planner could be used to perform several common tasks including those involving, pick-and-place, wiping and wrapping motions.

Testing is an integral part of a satellite’s development, requirements verification and risk mitigation efforts. A robust test program serves to verify construction, integration and assembly workmanship, ensures component, subsystem and system level functionality and reduces risk of mission or capability loss on orbit. The objective of this thesis was to develop a detailed test program for pico-satellites with a focus on the Cal Poly CubeSat architecture. The test program established a testing baseline from which other programs or users could tailor to meet their needs. Inclusive of the test program was a detailed decomposition of discrete and derived test requirements compiled from the CubeSat and Launch Vehicle communities, military guidelines, and industry standards. The test requirements were integrated into a methodical, efficient and risk adverse test flow for verification.

This project develops a quantitative method to evaluate the seismic risk for portable GSE at Vandenberg Air Force Base. Using the latest probability data available from the USGS, risk thresholds are defined for portable GSE having the potential to cause a catastrophic event. Additionally, an example tool for design engineers was developed from the seismic codes showing the tipping hazard case can be simplified into strict geometrical terms. The misinterpretation and confusion regarding the Range Safety 24 Hour Rule exemption can be avoided by assessing seismic risk for portable GSE. By using the methods herein to quantify and understand seismic risk, more informed risk decisions can be made by engineering and management. The seismic codes and requirements used and referenced throughout include but are not limited to IBC, ASCE 7, EWR 127-1, and AFSPCMAN 91-710.

Unmanned Aerial Systems (UAS) are a growing asset. Currently UAS are on the cutting edge with resources being spent developing the capabilities mostly for military use. This project is intended to create a system for non-defense customers. Specifically, the Operationally Responsive Aircraft (ORA) will appeal to academic institutions, individual consumers, future customers new to the UAS industry, as well as anybody trying to get airtime for custom sensors. The system developed in this project utilizes dual aluminum external payload bays attached to a ParkZone Radian aircraft. Each external payload bay can contain approximately 500 $\text{cm}^3$, with a height and width limit of 4.1 cm and 11.0 cm respectively. The custom sensors must weigh less than or equal to 3.2 lbs combined. The external payload bays were designed to hold an imaging payload which produces a composite map of the land surveyed. The system incorporates an Arduino Uno, SD Shield, as well as a CMOS camera and board. The processor saves individual images to an SD card. Once the aircraft has landed, the operator combines the images with Microsoft Research Image Composite Editor to create the composite map. This imaging payload has a NIIRS value of 4.0 +/- 0.4, which is equivalent to identifying a basketball court within a residential environment.

The Naval Postgraduate School is currently developing their first CubeSat, the Solar Cell Array Tester CubeSat, or NPS-SCAT. Launching a CubeSat, such as NPS-SCAT, requires environmental testing to ensure not only the success of the mission, but also the safety of other CubeSats housed in the same deployer. This thesis will address the development of CubeSat vibration testing methodology at NPS, including subsystem testing, engineering unit qualification, and flight unit testing. In addition, the new Cal Poly CubeSat Test POD Mk III will be introduced and evaluated based upon comparison with the Poly Picosatellite Orbital Deployer (P-POD). Using examples from the development of NPS-SCAT and test data from Cal Poly’s Test POD Mk III and P-POD, the current CubeSat testing methodology will be verified and an improved method for NPS CubeSat subsystem testing will be presented.

Optimal parametric design of a system must be able to respond quickly to short term needs as well as long term conditions. To this end, we present an Assess-Predict-Optimize (APO) strategy which allows for easy modification of a system’s characteristics and constraints, enabling quick design adaptation. There are three components to the APO strategy: Assess - extract necessary information from given data; Predict - predict future behavior of system; and Optimize – obtain optimal system configuration based on information from the other components. The APO strategy utilizes three key mathematical ingredients to yield real-time results which would certainly conform to given constraints: dimension reduction of the model, a posteriori error estimation, and optimization methods. The resulting formulation resembles a bilevel optimization problem with an inherent nonconvexity in the inner level. Using a simple infiltration-evaporation model to simulate an irrigation system, we demonstrate the APO strategy’s ability to yield real-time optimal results. The linearized model, described by a coercive elliptic partial differential equation, is discretized by the reduced-basis output bounds method. A primal-dual interior point method is then chosen to solve the resulting APO problem. / Singapore-MIT Alliance (SMA)

Truely optimal solutions to system design can only be obtained if the entire system is considered. In this research we consider design of commercial aircraft, but we expand the system to include a family of planes. A multidisciplinary design optimization framework is developed in which multiple aircraft, each with different missions, can be optimized simultaneously. Results are presented for a two-member family whose individual missions differ significantly. We show that both missions can be satisfied with common designs, and that by optimizing both planes simultaneously rather than following the traditional baseline plus derivative approach, the common solution is vastly improved. The new framework is also used to gain insight to the effect of design variable scaling on the optimization algorithm. / Singapore-MIT Alliance (SMA)

Multi-trailer articulated heavy vehicles (MTAHVs) exhibit unstable motion modes at high speeds, including jack-knifing, trailer swing, and roll-over. These unstable motion modes may lead to fatal accidents. On the other hand, these vehicle combinations have poor maneuverability at low speeds. Of all contradictory design criteria of MTAHVs, the trade-off relationship between the maneuverability at low speeds and the lateral stability at high speeds is the most important and fundamental. This trade-off relationship has not been adequately addressed. The goal of this research is to address this trade-off relationship through the design optimization of MTAHVs with active safety systems. A parallel design optimization (PDO) method is developed and applied to the design of MTAHVs with integrated active safety systems, which involve active trailer steering (ATS) control, anti-roll (AR) control, differential braking (BD) control, and a variety of combinations of these three control strategies. To derive model-based controllers, a single-trailer articulated heavy vehicle (STAHV) model with 5 degrees of freedom (DOF) and a MTAHV model with 7 DOF are generated. The vehicle models are validated with those derived using a commercial software package, TruckSim, in order to examine their applicability for the design optimization of MTAHVs with active safety systems. The PDO method is implemented to perform the concurrent design of the plant (vehicle model) and controllers. To simulate the closed-loop testing maneuvers, a driver model is developed and it is used to drive the virtual vehicle following the prescribed path. Case studies indicate that the PDO method is effective for identifying desired design variables and predicting performance envelopes in the early design stages of MTAHVs with active safety systems. / UOIT