Plastic Recycling, Carbon Capture and Disaster Relief through Pyrolysis (Year 2)

Project number
26033
Organization
PeakView Environmental Solutions
Offering
ENGR498-F2025-S2026
The management of plastic and other hydrocarbon waste is one of the most pressing issues of our civilization. As these often harmful materials break down, they pollute our air, water, and soil. Unsuspecting wildlife often succumbs to this waste due to suffocation, blockage, or entanglement. To alleviate these issues, PeakView Environmental Solutions aims to develop a mobile pyrolysis and oil refining plant that can be shipped to small, underdeveloped islands and areas that have recently been hit by natural disasters and are struggling with the supply of clean drinking water, electricity, and fuel. By utilizing the often abundant organic waste, such as plastic, tires, and plant debris, locals can produce their own biofuel and run power generators for water pumps, filters, and other emergency equipment.

The goal of this project is to improve the existing pyrolysis reactor design in terms of durability, portability, safety, temperature consistency, and user friendliness. The existing system takes plastic and other organics as input and produces a flammable hydrocarbon liquid as output. The first-year team was able to design and build a functional prototype which can now be taken as a proof of concept and iterated to the next level. This year’s goal is to use the resulting design to manufacture a first batch of units that can be shipped to communities in need. The project will require mechanical engineering for the durability and portability improvements, biosystems engineering for the safety requirements, electrical engineering for the control mechanisms that will enable the temperature consistencies, and industrial engineering for the user friendliness.

Scope: (1) Research the pyrolysis process for plastic and determine how best to improve the metrics of durability, portability, safety, temperature consistency, and user friendliness. (2) Confirm your understanding with the relevant university support staff. (3) Design new components for the system as needed. Consider off-the-shelf technology first and find customized solutions as needed. (4) Redesign existing components for optimal usage in the field. (5) Create the Job Safety Analysis (JSA) document required for component and system testing. (6) Provide mechanical, environmental, and electrical diagrams of the system’s working components and processes. (7) Test the system for performance, safety, and ease of use and iterate on previous steps until an optimal design is found. (8) Present results in a video conference and PowerPoint presentation.

Coanda-Directed Compressor Hub Cavity Injection

Project number
26032
Organization
Honeywell Aerospace
Offering
ENGR498-F2025-S2026
The team will be expected to design, analyze, and wind-tunnel test a model that develops the understanding of the benefits of using the Coanda effect to minimize the negative impact of compressor hub cavity recirculation into the main gas path of a turbofan high pressure compressor. The team will need access to software to create 3D models and to execute computational fluid dynamics (CFD) and finite element (FEA) analyses. A preliminary statement of work includes:
1) Perform aerodynamic and mechanical analyses of an airfoil cascade at predicted rig test condition without hub injection. Includes method of assembly and installation into Educational Wind Tunnel
2) Design a pressurized secondary flow system that can introduce the stator hub flow during testing of the model in the Educational Wind Tunnel
3) Update the aerodynamic model to include stator hub injection representative of current and Coanda-influenced configurations
a. This model may need to be simplified as a simple source term at the hub as opposed to modeling the geometry depending on CAD/CFD proficiency
4) Manufacture or procure all test hardware including instrumentation to measure cascade exit conditions and quantify the benefit of the Coanda-directed design
a. Many of the parts may be 3D printed, including the airfoil
5) Analyze the data, make comparisons to analytical predictions, and generate a final report that describes the program, the benefits of the Coanda-directed design, and any recommendations based on lessons learned during the project

Unmanned Aircraft Anomaly Scenario Playback Tool

Project number
26030
Organization
Acron Aviation
Offering
ENGR498-F2025-S2026
Acron Aviation is implementing ACAS Xu, a next-generation collision avoidance capability for unmanned aircraft. This function may be hosted on several multiple different radio platforms currently produced by Acron Aviation. Currently, when an anomaly occurs in the field or at the customer site, there is not a mechanism that can appropriately “playback” the offending scenario at the Acron Aviation site. These scenarios would involve “intruder” aircraft that enter the collision protection area around the aircraft, and post-flight analysis of the scenarios helps validate the ACAS Xu algorithms and improves safety of aircraft operations.

Composite/Metallic Stator for Turbofan Engine

Project number
26029
Organization
Honeywell Aerospace
Offering
ENGR498-F2025-S2026
The team will be expected to explore various materials and manufacturing methods for a hybrid composite/metallic stator for turbofan engines and evaluate the potential for real-world implementation. In this process, the team should be mindful of business considerations such as cost and weight. The team will need access to software to create 3D models and to execute computational fluid dynamics (CFD) and finite element (FEA) analyses. A preliminary statement of work includes:
1) Research current production standard composite stator manufacturing strategies to understand its advantages and disadvantages, including the necessity of a metallic reinforced leading edge to protect against erosion.
2) Research alternative composite manufacturing methods that could be applied in the context of turbofan engine stators, with special consideration for the metallic leading edge and possible alternatives.
3) Develop/choose at least one new composite/metallic manufacturing strategy that the team is capable of testing.
4) Perform mechanical analyses of stators for both the current and new manufacturing strategies; adjust the new strategy as needed.
a. If adjustments need to be made to the design/airfoil shape of the stator, or if the new strategy shows concern for geometric tolerances, model and evaluate the aerodynamic impact.
5) Manufacture or procure all necessary hardware (e.g., composite molds, mounting fixtures, metallic stator components, etc.) to develop stators with the new composite/metallic manufacturing strategy.
6) Conduct static loading tests and impact tests (if possible) to assess stator strength and compliance with foreign object debris (FOD) requirements.
7) Analyze the data and generate a final report that describes the program, the benefits, drawbacks, and risks for the new composite/metallic manufacturing strategy, and any recommendations based on lessons learned during the project.

The team is expected to prioritize the items in the statement of work above; however, the team may choose to explore additional relevant objectives if time permits. These optional objectives include:
1) Research considerations and limitations of sustained and repeated high temperature (200-800 deg. F) interactions for the composite/metallic stator.
2) Simulate and/or test sustained and repeated high temperature interactions for the current and/or new composite/metallic stator and evaluate the impact on the strength and geometric tolerances of the stator.
3) Develop one or more additional composite/metallic manufacturing strategies that would improve the thermal capabilities of the stator.
4) Simulate and/or test sustained and repeated high temperature interactions for the additional composite/metallic stator and evaluate the impact on the strength and geometric tolerances of the stator.

Whisper Trim

Project number
26028
Organization
Whisper Wild
Offering
ENGR498-F2025-S2026
This project will benefit neurodiverse children and families struggling with fear-based grooming routines, helping turn hygiene tasks into emotionally positive, independent moments. It supports UArizona’s mission in healthcare innovation, neurodiverse inclusion, and real-world design for underserved populations.

Background and Need: Whisper Wild was created in response to a traumatic haircut experience suffered by a young boy named Luke during a sensory meltdown. His story is one of many that demonstrate how traditional grooming tools can overwhelm and harm children with autism or sensory processing disorders. These children often experience grooming tasks — like nail trimming or haircuts — as physically painful or emotionally threatening events due to hyper-sensitivities to noise, touch, and unpredictability. These are not small inconveniences; they are major barriers to safety, hygiene, and dignity. Whisper Wild provides an emotionally safe and sensory-informed alternative through ergonomic, animal-themed grooming tools that incorporate soft materials, lights, sounds, and tactile cues to guide participation and reduce fear.

Project Description: The goal is to design, prototype, and refine two sensory-safe grooming products for children ages 3–10:
1. Whisper Wild Critter Clippers – Manual, animal-shaped nail trimmers featuring rounded PDV-coated ceramic blades, sensory feedback (LED eyes and sounds), and a nail detection sensor. A silicone-textured outer shell improves grip and sensory comfort. Swappable cradle inserts support both finger and toe trimming with a length range of 1.02.0 mm. A light-up button and LED feedback help children know when the clipper is properly positioned. A nail catcher is built into the belly for hygienic cleanup.
2. Whisper Wild Tiny Tame Buzzers– Electric hair trimmers using an internal cradle system to isolate vibration and reduce auditory overstimulation. They include low-noise motors, animal-inspired ergonomic casing, LED visual cues, and calming sound modules. Swappable comb guards support different hair lengths. These are USB-C rechargeable and waterproofed for home use.

***This project is conducting remote interviews. Please visit https://bit.ly/Whisper26028 to schedule a time to speak to the sponsor***

Durability Test Apparatus for SynCardia's Emperor Total Artificial Heart (ETAH)

Project number
26027
Organization
SynCardia Systems
Offering
ENGR498-F2025-S2026
SynCardia is developing the “Emperor” Total Artificial Heart (ETAH), a next-generation total artificial heart (TAH). The Emperor TAH is based off of the existing, clinically proven design of the SynCardia Total Artificial Heart (STAH), utilizing the same materials, geometry, and components for all blood-contacting portions of the device. The Emperor TAH, while incorporating these attributes, upgrades the drive mechanism from a pneumatic design to a mechanically actuated one, which results in significant improvements in portability, efficiency, noise, heat, and reliability.

This new device, while similar to the current STAH system, will require new verification activity to demonstrate system reliability for durable implantation. While the current mock circulatory loop used to verify the function of the STAH is effective at simulating a wide variety of physiological conditions, it is complex, relatively large, and limited to just one artificial heart. SynCardia is tasking the capstone team with the design, construction, and qualification of a new test apparatus that will be able to simulate patient physiology for a number of ETAH test units that allow the new system to demonstrate reliability and functional equivalence with the on-market STAH.

The test apparatus shall:
• accurately simulate normotensive patient physiology (including pressures, resistances, flow rates, temperatures, and fluid exposure/submersion) for the duration of testing
• allow for the successful attachment and function of enough test units to demonstrate reliability equivalence (mean time between failure) to the STAH with sufficient statistical confidence to support a regulatory submission
• allow for the tracking of device performance over time (pressures, flow rates, temperatures, power consumption, etc)

A successful test apparatus should:
• allow for the successful attachment and function of enough test units to demonstrate reliability equivalence (mean time between failure) to the STAH with sufficient statistical confidence with 1 year or less of testing
• allow for the simulation of patient pathophysiology, such as systemic and/or pulmonary hypertension, hypotension, and non-hypertensive hypervolemia

This test apparatus will need to be subjected to installation qualification, operational qualification, and performance qualification (IQ/OQ/PQ), and the verification protocols must be written and tested by the student team. This qualification and documentation will allow SynCardia engineers and technicians to conduct full verification testing of the new artificial heart design.

Turbofan Smart Mount

Project number
26026
Organization
Honeywell Aerospace
Offering
ENGR498-F2025-S2026
Honeywell is interested in designing a Honeywell Turbo Fan engine to support the next generation of airframes in the aerospace business jet markets. The engine will be attached to the airframe with a forward and an aft mount system.
The forward mount system is comprised of a structural yoke attached to the airframe and to the engine. This project uses a soft mount system, which allows a small amount of relative motion between the engine and the airframe. This reduces cabin vibration which results in less noise and fatigue for the passengers.
Upper and lower arrangements are first attached to the engine front frame, allowing the coupling of the yoke to the engine. These arrangements use a cylinder housing with an internal piston. The piston is arranged to have resistive spring force in both the up and down directions. A fluid is then pumped from above the piston to below the piston and vice versa, providing dampening. This fluid flow rate can be modified throughout the flight envelope to allow active dampening of this mount system.
This project will have a focus on the proof of concept. 3D printing and plastics are encouraged.
Design and build a proof of concept prototype of a soft mount, piston driven, variable fluid flow control system that is optimized to be lightweight while meeting the following objectives.

• A piston cylinder housing and cylinder cover that have a total height of 2.625”
• A piston with an outside diameter of 4.800”, a portion of the piston protrudes through the cylinder cover. A piston travel distance of +/- .175”
• A force of 5 lbs. +/- 2 lbs. to fully bottom the piston (piston travel = .175”), in either direction, with the manually controlled valve fully open (valve_open_force)
• A resistance force capable of 10X valve_open_force with the manually controlled valve fully closed and where the piston has not bottomed out (piston travel < .175”)
• Various seals preventing fluid depressurization above and below the piston.
• A bypass circuit allowing fluid to move from the top of the piston to the bottom of the piston and vice versa.
• A manually controlled valve allowing adjustments from fully open to fully closed of the fluid flow rate in the bypass circuit.
• At least one stiff and one soft coaxial Belleville (conical) washer resisting motion in both the piston up and piston down directions. The stiff spring rate approximately 2X the soft spring rate.

Hybrid Electric Drill Rig

Project number
26024
Organization
Geomechanics Southwest, Inc
Offering
ENGR498-F2025-S2026
Proof of Concept happened in school year 24-25.
Goal of 25-26 is to build off of this to make a fully operational Drill Rig that is powered by electric motor. This includes integration of hydraulic fluid.
ITAR Compliance & US Citizens are Required

Coral Reef Arks Hydrodynamics

Project number
26022
Organization
UA Biosphere 2
Offering
ENGR498-F2025-S2026
Shall propose three additional Arks designs
Shall test the proposed designs with the 1V and 2V geodesic spheres
Shall create a model demonstrating the hydrodynamic stability of each design
Shall build smaller-scale models of each design for wind tunnel and or in-water testing
Shall articulate the benefits and drawbacks of each design
Shall designate a standout design based on results

Get started and sponsor a project now!

UA engineering students are ready to take your project from concept to reality.