Project goal: To design an expansion to an existing production line that increases production of the flu vaccine by 50 million doses. A shortage of vaccines with the correct strand predictions has made the 2017-2018 flu season more severe than usual. The vaccine is mass produced by pharmaceutical companies throughout the world using the strains predicted by the World Health Organization. The new expansion sought to cut the production period in half. The new design allows the quadrivalent vaccines to be produced on eight lines,each including a virus injector, egg incubator, and egg harvester to create the initial vaccine serum,with two lines per strain. The process after the egg harvester involves several filtration techniques, including tangential flow filtration, ion exchange chromatography and size exclusion chromatography, which yield serum standards pure enough to be mixed with an excipient in order to be absorbed fully by a human body. The final 50 million doses will be sent to distributors, clinics and hospitals nationwide to solve the vaccine shortage.

Project goal: To design a process for removing arsenic from groundwater in the Black Canyon City area to meet maximum EPA contaminant limit standards. Arsenic occurs naturally in groundwater but is especially prevalent in areas near mining operations. Long-term arsenic exposure has been linked to severe medical conditions,including cancer. This project creates potable water by removing arsenic from groundwater via four major processes: chlorination, adsorption, desorption and precipitation. Chlorination oxidizes arsenic, disinfects water, and lowers pH for optimal arsenic removal. Adsorption uses granulated ferric hydroxide to remove arsenic from the water, leaving an arsenic content that is below the maximum containment level and safe for human consumption. Desorption is performed when the adsorbent is saturated with arsenic so that the granulated ferric hydroxide can be regenerated and reused. Desorption produces a concentrated arsenic brine that can be further treated to precipitate out the arsenic as a solid to be disposed of as hazardous waste.

Project goal: To almost double the capacity of the Greenfield Water Reclamation Plant to 30 million gallons of reclaimed water per day, and 16 million gallons of bio-solids per day. The aim of the project is to expand the current capacity of the Greenfield Water Reclamation Plant from 16 to 30 million gallons of Class A+ reclaimed water per day annual average day flow, or MGD AADF. At the same time,the project investigated an increase in Class B bio-solids from 8 to 16 MGD AADF. The expansion maintains the plant’s current Arizona Department of Environmental Quality standards, and does not disrupt existing operations. Historic flow and wastewater characteristic data were analyzed, as were the processes in the plant to reduce energy and chemical usage. The designed process treats the influent wastewater using a combination of screens, grit removal, hydrocyclone separators, clarifiers, aeration basins, disk filters, and ultraviolet disinfection to remove microbes from the effluent. The sludge is treated using centrifuges and anaerobic digesters, then the Class B bio-solids are sent to the landfill. The methane produced during this process is used to heat the boilers,which generate steam to heat the sludge. The excess methane is burnt off in flares. Chemicals used in the process include sodium hydroxide and sodium hypochlorite.

Project goal: To design and construct three sets of 35-degree swept wings with varying flexibility that are compatible with the X-56A MUTT fuselage. Although wings with high aspect ratios increase aerodynamic efficiency, the resulting large wingspans amplify the magnitudes of torsional and bending moments. The Dynamic Scaled Research Testbed is a one-third dynamically scaled fuselage modeled after the Lockheed Martin X-56A MUTT used to test these dynamic interactions. Analytical methods are used to determine the required geometric and material properties of three different sets of spars, which dictate the stiffness of the corresponding wing. These analytical methods are then verified using numerical finite element analysis and ground testing. Sensors and additional avionics were designed and installed to record telemetry and flow conditions over the wing during flight-testing. Following extensive structural and electronic ground testing, flight tests were performed to validate the design and gather data for research. The upgraded testbed will allow researchers to gather flight data and contribute to the safe and effective use of flexible wings with high aspect ratios.

Project goal: To design a large-scale unmanned aircraft system to support flight-testing of newly designed parachute-recovery system. To help mitigate the costs arising from failure of large-scale unmanned aircraft systems, the team designed the testbed to flight-test the autonomous parachute system designed by Team 17078.A four-foot-diameter hexacopter was designed and built using mostly existing hardware. The structure was designed to protect essential, and costly,components from damage while allowing the inexpensive and easily replaceable frame to absorb the impact. Structural integrity was analyzed using finite element analysis. Motor testing was performed to validate the thrust outputs of all six motors to ensure accurate performance capabilities. Control configuration and system integration were finalized before flight-testing.The hexacopter design satisfied the requirements for parachute flight-testing.

Project goal: To design, build and test a high-endurance, low-cost unmanned aircraft system to explore and map difficult or remote terrain without disturbing wildlife or the environment. The final design selected is a vertical takeoff and landing unmanned aircraft that can adjust the motor power distribution to fly as a fixed-wing aircraft. While soaring at cruise, the aircraft uses its carbon-fiber air frame and airfoil to maximize lift coefficients, plus a high-capacity lithium polymer battery for a flight time of 30 minutes. After arriving at its destination, it transitions to a quadcopter, and produces high-resolution photographs and first-person view video through an on board flight computer system. Three different iterations of the aircraft, with increasing stability and performance, were designed, built and tested.

Project goal: To merge the best aspects of fixed-wing aircraft and rotorcraft into a single unmanned aircraft system that can efficiently perform the roles of both types of aircraft. In emergency search and rescue, fixed-wing aircraft conduct high-pass surveys over a large geographical area to locate injured people. Rotorcraft are then called in to provide aid or assess injuries in greater detail. The unmanned aircraft system designed can hover and take off and land vertically while still being able to travel long distances efficiently. It has an aerodynamically optimized flying wing lifting-body geometry with a carbon composite construction. Four central-ducted fans produce the majority of thrust during vertical flight and are assisted by two thrust-vectoring wing pods, one on each wing tip. During horizontal flight the wing pods rotate to provide forward thrust. The design reduces total system weight by 35 percent when compared to previous design iterations, while still providing increased overall performance. Flight-testing demonstrated that implementing an autopilot system made the aircraft more stable and easier to control.

Project goal: To design a radio-controlled aircraft to AIAA requirements that helps simulate a cargo and passenger aircraft with fully integrated line-replaceable units. The American Institute of Aeronautics and Astronautics Design/Build/Fly is an annual competition that provides students with real-world experience by giving them the opportunity to validate their analytic studies.The objective of the 2018 competition reflects a demand in the aeronautical industry for line-replaceable units, which are components of an assembly that, upon failure, can easily be replaced to bring the assembly back to full functionality. Normally, any failed component means grounding the aircraft and shipping it to a repair facility for extensive and expensive repair. Line-replaceable units can be easily replaced on the line (airport) and the aircraft recommissioned, saving money, frustration and time. The team competed in Wichita, Kansas in April 2018 against national and international schools in a competition that featured ground and air missions to demonstrate the capabilities of the aircraft.

Project goal: To design, build and test a detailed control system within a wing model to discover the wing’s aerodynamic characteristics, such as frequency and flutter. A closed-loop system was designed and implemented that would allow the wing to correct itself and remove any unnecessary flutter while optimizing flight conditions. The objective of this design is a closed-loop control system that stabilizes the wing section when the angle of attack is disturbed from its desired position. Sensors were placed on the top and bottom surfaces to measure the free stream velocity. Sensor data is sent to a proportional integral derivative controller, which generates the desired values.

Project goal: To take raw borehole data and design a mine based on given constraints, such as time and man-hour restrictions. Borehole data was converted into a geologic block model, complete with ore grades. Using advanced 3-D modeling software and the block model data, pit push-backs were designed and a life-of-mine plan was developed. Concurrently, a wash-plant upgrade and crusher overhaul were designed by analyzing the overall tons mined per hour. The final part of the design included coordination and design of haulage paths, recommendations for fleet upgrades and purchases, and design of waste storage dump piles. The final design resulted in a mine life of 71 years.This project was submitted for the 2017-2018 Society for Mining, Metallurgy and Exploration/National Stone, Sand and Gravel Association Student Design Competition.The team placed within the top six teams internationally.