SEMILITHO: Semiconductor Lithography Tool Prototype

Project number
25511
Organization
UA Materials Science and Engineering
Offering
ENGR498-S2025-F2025
The goal is to develop a table-top, compact, simple, portable photolithography tool prototype capable of patterning basic designs on small wafers with micron-scale precision. The prototype will be used as an educational and training resource for semiconductor device fabrication in coursework and outreach activities at the University of Arizona.

Dental Instruments Design to Reduce Hand Fatigue

Project number
25510
Organization
Tucson Biological Dentistry
Offering
ENGR498-S2025-F2025
1. Work with dentist at Tucson Biological Dentistry (TBD) to understand how the dental instruments are used and held by dental professionals during the dental procedures. Tucson Biological Dentistry will provide samples of different types of dental instruments that are used during the dental procedures.
2. Understand the current design of dental instruments and how a new design will help to minimize strain that can play a pivotal role in reducing hand and wrist issues during dental procedures. Dental procedures often require continuous, repetitive movements such as drilling, scaling, and polishing.
3. Evaluate existing dental instruments to determine if new dental instruments need to be designed or existing instruments can be modified.
4. Design a setup that allows evaluation of hand/thumb/joint stress and fatigue when dental instruments are being used.
5. Build prototype instruments that can withstand high temperatures between 121C to 134C in an autoclave unit.
6. Determine if new instruments need to be developed or only a handle that could fit over the handle of current instruments.
7. Develop design fabrication method.
8. Test dental instruments in dental offices with dentists, dental hygienist, and dental assistants.
9. Develop a plan to turn the lab prototype into marketable dental instruments available to other dental professionals.
10. Develop results in a video and power point presentation that can be present to people in the dental field to explain how the newly developed instrument will be more ergonomic and mitigate hand and wrist pain.

Solar Panel Cleaning Drone

Project number
25509
Organization
Vijayan Chomatil - Project Sponsor
Offering
ENGR498-S2025-F2025
The accumulation of dust, dirt, and debris on solar panels can significantly reduce their efficiency, with losses ranging from 3% to 10%. Cleaning these panels regularly is critical to maintaining optimal performance. However, solar panels are often installed in hard-to-reach locations, such as rooftops, parking awnings, and remote solar farms, making manual cleaning labor-intensive, costly, and potentially hazardous.

This project aims to develop an innovative autonomous drone designed to clean solar panels efficiently, safely, and cost-effectively. The drone will be equipped with advanced sensors, AI navigation systems, and a specialized cleaning mechanism tailored for non-invasive cleaning of photovoltaic surfaces. Key features of the drone include:

- Autonomous Navigation: Using LiDAR, GPS, and machine vision, the drone will map and navigate complex solar installations, ensuring comprehensive cleaning coverage.

- Non-Invasive Cleaning Mechanism: The drone will employ a combination of soft brushes, microfiber rollers, and water misting (or an air-based system for water-constrained areas) to remove dirt without damaging the panel surface.

- Energy Efficiency: The drone will be battery-powered, with optional integration for solar charging, ensuring sustainability and compatibility with renewable energy goals.

- Remote Monitoring and Control: A user-friendly interface will enable operators to schedule cleaning tasks, monitor drone performance, and receive efficiency reports remotely.

- Adaptability to Various Environments: The drone will be designed to operate in diverse conditions, including extreme temperatures, high wind, and uneven terrain.
By automating the cleaning process, this drone will reduce maintenance costs, improve safety for workers, and ensure solar installations consistently operate at peak efficiency.

This project addresses a critical challenge in renewable energy systems and supports the transition to sustainable energy solutions.

3D Printer Plastic Filament Shredder

Project number
25508
Organization
Engineering Design Center
Offering
ENGR498-S2025-F2025
Project Scope: Academic makerspaces, such as the Engineering Design Center and CATalyst Studios, generate significant plastic waste from 3D printing, particularly due to novice users learning the process. While recycling this waste is possible, traditional recycling equipment is often bulky and expensive, limiting accessibility in these settings. This project seeks to address this issue by developing a compact, desktop plastics shredder specifically designed to process waste from 3D printers. The initial focus will be on PLA, a commonly used material in 3D printing.

Description:
The project aims to reduce plastic waste in academic makerspaces by designing and prototyping a desktop shredder tailored for recycling 3D printer materials like PLA. By collaborating with professors and leveraging community resources, the team will create a cost-effective and user-friendly solution that integrates seamlessly into makerspace environments. The results, including designs and technical documentation, will be open-sourced to encourage broader adoption. Future plans include expanding the shredder’s capabilities to process other types of plastic, supporting a more sustainable approach to 3D printing.

Scope: (1) Work with Professor Briggs, to understand the current plastics recycling machinery used and the open-source information available. (2) Evaluate existing information and projects to draw inspiration and resources. (3) Design a plastic shredder to process PLA plastic filament. (4). Build a prototype desktop plastic shredder, complete with mechanical, electrical diagrams, and source code. (5) Test system with supplied material and iterate on previous steps until issues are resolved. (7) Document project and resources to be distributed to an open-source community. (8) Present results in a video documentation and website for the UArizona community and the general public.

3D Printing and Topological Optimization - The Holy Grail of Additive Manufacturing

Project number
25507
Organization
Cummings Aerospace
Offering
ENGR498-S2025-F2025
Problem Statement:
With the advent of 3D printing, it is possible to fabricate component designs that until now have been impossible to make. In addition to the 3D printing capabilities that now exist, analysis software also exists that performs Topological Optimization, routines that minimize the use of the material used in fabrication. This combination of 3D Printing and Topological Optimization is the Holy Grail of additive manufacturing. There is one problem, however. The topological optimization generally results in a solid structure, but the 3D printers have the ability to create components that have variable amounts of internal structure to optimize print time and minimize material usage. And these components may perform very differently in use when compared to the solid structure previously analyzed.

Project: Develop a method to perform structural analysis of 3D printed polymers (PLA, ULTEM) using FDM processing. Produce prototype hardware to demonstrate the methodology. And document the methodology such that the approach can be integrated with other analysis tools, like Ansys and SolidWorks.

Skills Required: Structural analysis experience using Finite Element modeling (FEM), working knowledge of 3D printing (slicers, printers, etc), experience with CAD software (Solidworks, Creo, Inventor, etc), and experience with analysis software (Ansys, Simulia, etc).

Ground Transport and Mission Support System for a Mobile 2-meter Cassegrain Telescope

Project number
25506
Organization
Leading Edge Aviation Consulting
Offering
ENGR498-S2025-F2025
There is significant demand for Cassegrain reflecting telescopes in the 2-meter range to provide astronomical viewing for education and research. These telescopes are larger and more expensive than the range traditionally utilized by amateurs, but smaller and more economical than larger telescopes that are very complex and require immense, permanent facilities and support equipment to house and operate the device. Optimal viewing conditions for ground based telescopes are usually found at high altitudes with dry, low-humidity conditions and in locations that have predominantly clear weather. Consequently these locations are frequently the top of mountains that have fragile ecosystems and many times hold cultural importance by indigenous groups. Environmental impact studies and overcoming political barriers are significant challenges.
A design for a mobile telescope would overcome many of these issues and allows the telescope to be rapidly relocated and deployed to take advantage of optimal viewing conditions.

Conceptual Design of a Heavy Cargo Lunar Lander

Project number
25505
Organization
Paragon Space Development Corp.
Offering
ENGR498-S2025-F2025
Paragon aims to develop the concept of an unmanned heavy cargo spacecraft, designed to be launched aboard SpaceX's Starship rocket in the 2030 timeframe. The project, titled Paragon Lunar Unmanned Super Heavy Cargo (PLUSH), is in its early stages and requires a complete design effort. To provide a vision for the concept, an AI-generated image has been included as a conceptual illustration.

The first phase of the project will focus on defining requirements and creating a preliminary design for the vehicle. PLUSH will be an unpressurized and environmentally uncontrolled spacecraft, exclusively transporting lunar equipment rather than humans. Its mission will be to deliver several tons of cargo to the Moon, forming part of the foundational infrastructure needed to support a new lunar economy.

This effort will specifically focus on the Lander Structure and Frame, encompassing:
* Landing Gear: Including shock-absorbing legs and footpads.
* Primary Structure: Housing all subsystems and supporting vehicle integrity.
* Starship Interface: Ensuring compatibility with SpaceX's rocket for launch.
* Cargo Bay Design: Proposing an organizational layout for storage pods and deployment mechanisms.
* Volume Allocation: Providing space for propulsion systems and other subsystems.
* Deployment Systems: Designing a ramp for unloading cargo.
* Safety and Telemetry: Incorporating essential safety and communication components.
The design will remain at a high level, targeting Preliminary Design Review (PDR) maturity. Detailed designs are not required, and all elements are open to trade studies to optimize for volume, weight, and performance.

The student team will have significant creative freedom in proposing the overall design and architecture for PLUSH. However, the vehicle must meet key requirements:
* Withstand launch loads and fit within the Starship payload bay.
* Interface effectively with the Starship for deployment.
* Maximize cargo capacity.
* Survive descent and landing procedures on the lunar surface.
This project offers an exciting opportunity to contribute to the conceptualization of a critical component in future lunar operations.

Design and Validation of a Lateral Flow Assay Device for Neonatal Bilirubin

Project number
25504
Organization
Picterus AS
Offering
ENGR498-S2025-F2025
Design and evaluation of a lateral flow test device for Point-of-Care neonatal bilirubin measurement in regions with limited access to lab testing. High levels of bilirubin in the bloodstream cause jaundice, and can lead to severe disability and sometimes death when timely treatment is not administered. This test will work with Picterus's smartphone app to allow rapid bilirubin measurement by caretakers for newborns in regions where lab testing of blood samples is not readily available.

Students will select appropriate test strip materials from several commercially available options and evaluate fabrication methods based on performance and cost considerations. Students will design a plastic clip that will be used to attach the lateral flow test strip to Picterus's calibration card for use with Picterus's mobile app. The mobile app allows a user to take photos of the lateral flow test strip and calibration card using a smartphone's camera and calculates the level of bilirubin in the blood. The plastic clip will be designed to accept a small blood sample and expose the lateral flow test strip to the blood in a controlled manner. The clip and test strip performance will then be tested together using the Picterus mobile app in a lab setting.

Racing the Sun – Autonomously

Project number
25503
Organization
UA Department of Systems and Industrial Engineering
Offering
ENGR498-S2025-F2025
The objective of this project is to develop reliable autonomous (automated) driving capabilities to the ‘Racing the Sun’ solar vehicles. Racing the Sun (https://sarsef.org/programs/competitions/racing-the-sun/) is a STEM event where regional high school teams convert gasoline-powered go karts into solar-powered race cars and then compete in an annual race event at Musselman Honda race track. Students assemble and test the vehicles before the big race day. At the race, student teams compete in different divisions to see who can run the longest and furthest. The goal of the Engineering Senior Design project is to develop an autonomous driving racing the sun go cart. At the end of the project the Engineering Senior Design team will demonstrate the reliable self-driving capability by having their vehicle complete one or more laps at the Musselman Honda racetrack.

The project will require the team to develop the mechanical steering and speed control systems, select and add sensors (video, lidar, radar, and/or GPS), and develop a self-driving stack (software) that can successfully control the vehicle around the Musselman Honda racetrack. GPS is not accurate enough for vehicle control, so other sensors are needed to sense the roadway and plan the driving path. For this project, there will not be any obstacles or other vehicles on the track when the vehicle is operating in autonomous mode.

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