Honeywell is currently extending the reach of additive manufacturing (AM) in its product line and expects to produce as much as 40% of its inventory through AM in five years. Additive manufacturing itself is expected to grow into a $3.1 billion dollar industry in the next 5 to 10 years. Reusing IN 718 powder, a nickel-based super alloy metal powder, is an ideal option to reduce costs as well as reduce waste because it can be used with additive manufacturing, but the main obstacles are lack of procedure standardization and product quality assurances from this process. The goal of the capstone project, "Effect of Powder Reuse on DMLS (Direct Metal Laser Sintering) Product Integrity," is to create a powder characterization protocol in order to determine if the IN 718 powder can be reused and what effect the IN 718 reused powder has on the mechanical properties of the products Honeywell fabricates. To provide context and impact of this capstone project, this paper serves to identify the benefits of AM for Honeywell and the cost effectiveness of reusing the powder versus using virgin powder every time. It was found that Honeywell's investment in AM is due to the cost effectiveness of AM, versatility in product design, and to ensure Honeywell remains competitive in the future. In terms of reducing expenses, reusing powder enables costs to be approximately 45% less than using virgin powder. With these key pieces of information, the motivations for this capstone project are understood to a fuller and more profound degree.

The purpose of this honors project is to analyze the difference between different powder separation techniques, and their suitability for my capstone project – ‘Effect of Powder Reuse on DMLS (Direct Metal Laser Sintering) Product Integrity’. Due to the nature of my capstone project, my group needs to characterize foreign contaminants in IN 718 (Ni-based superalloy) powder with a mean diameter around 40um. In order to clearly analyze the contaminants and recycle useful IN 718 powders, powder separation is favorable since the filtered samples will be much easier to characterize rather than inspect all the powders at once under microscope. By conducting literature review, I found that powder separation is commonly used in Geology, and Chemistry department. To screen which combination of techniques could be the best for my project, I have consulted several research specialists, obtained adequate knowledge about powder separation. Accordingly, I will summarize the pros and cons of each method with regard the specific project that I am working on, and further explore the impacts of each method under economical, societal, and environmental considerations. Several powder separation techniques will be discussed in details in the following sections, including water elutriation, settling column, magnetic separation and centrifugation. In addition to these methods, sieving, water tabling and panning will be briefly introduced. After detailed comparison, I found that water elutriation is the most efficient way to purity IN718 powder for reuse purpose, and recovery rate is as high as 70%, which could result in a significant reduction in the manufacturing cost for Honeywell since currently Honeywell only use virgin powders to build parts, and 90% of the leftover powders are discarded.

The work for this thesis was done in conjunction to that of my capstone project, which focused on understanding the effects of powder re-use on products built via Direct Metal Laser Sintering (DMLS), a specific additive manufacturing (AM) technique where powder particles are sintered together to form final parts. Honeywell Aerospace helped support this research by providing materials and mentorship; this work will play a key role in their decision to implement DMLS and other AM methods on a larger scale. Whereas the capstone focuses on the technical details of constructing characterization equipment, analyzing data, and formulating a concluding recommendation on whether the powder can be re-used, the thesis attempts to put this body of work in its greater context, surveying the economic and environmental effects of additive manufacturing technologies with a slant towards the aerospace industry. Shifts in the supply chain with aircraft parts and how this affects costs are explored, as well as how the quality and reliability of additively manufactured parts differs from their traditionally manufactured counterparts and the effects of this on related industries and purchasers.

The goal of the paper was to examine the fatigue mechanisms of polymers and silicone based elastomers. The mechanisms of fatigue due to crazing: the alignment of polymer chains to the stress axis, and shear banding: the localized orientation of the polymer by the shear stresses from two planes, were discussed in depth in this paper. Crazing only occurs in tensile stress, is initiated on the surface of the material, and only occurs in brittle polymers. Crazing also accounts for a 40-60% decrease in density, causing localized weakening of the material and a concentration in stress. This is due to a decrease in effective cross sectional area. The mechanism behind discontinuous growth bands was also discussed to be the cause of cyclic crazing. Shear banding only occurs in ductile polymers and can result in the failure of polymers via necking. Furthermore, the high fatigue resistance of silicone elastomers was discussed in this paper. This conclusion was made because of the lack of fatigue mechanisms (crazing, discontinuous growth bands, and shears banding) in the observed elastomer's microstructure after the samples had undergone fatigue tests. This was done through an analysis of room temperature vulcanized silicone adhesives, a heat-curing silicone elastomer, and a self-curing transparent silicone rubber. Fatigue of room temperature vulcanized silicon was observed, however this was reasoned to be the failure of the adhesion of the elastomer to the steel substrate instead of the microstructure itself. Additionally, the significance of fatigue in real world applications was discussed using SouthWest Airlines Flight 812 as an example.

The vastly growing field of supercomputing is in dire need of a new measurement system to optimize JMRAM (Josephson junction magnetoresistive random access memory) devices. To effectively measure these devices, an ultra-low-noise, low cost cryogenic dipping probe with a dynamic voltage range is required. This dipping probe has been designed by ASU with <100 nVp-p noise, <10 nV offsets, 10 pV to 16 mV voltage range, and negligible thermoelectric drift. There is currently no other research group or company that can currently match both these low noise levels and wide voltage range. Two different dipping probes can be created with these specifications: one for high-use applications and one for low-use applications. The only difference between these probes is the outer shell; the high-use application probe has a shell made of G-10 fiberglass for a higher price, and the low-use application probe has a shell made of AISI 310 steel for a lower price. Both types of probes can be assembled in less than 8 hours for less than $2,500, requiring only soldering expertise. The low cost and short time to create these probes makes wide profit margins possible. The market for these cryogenic dipping probes is currently untapped, as most research groups and companies that use these probes build their own, which allows for rapid business growth. These potential consumers can be easily reached by marketing these probes at superconducting conferences. After several years of selling >50 probes, mass production can easily become possible by hiring several technicians, and still maintaining wide profit margins.

A novel approach, the Invariant Based Theory of Composites and the "Trace" method it proposes, has the potential to reduce aerospace composite development times and costs by over 30% thus reinvigorating the development process and encouraging composite technology growth. The "trace" method takes advantage of inherent stiffness properties of laminates, specifically carbon fiber, to make predictions of material properties used to derive design allowables. The advantages of the "trace" theory may not necessarily be specific to the aerospace industry, however many automotive manufacturers are facing environmental, social and political pressure to increase the gas mileage in their vehicles and reduce their carbon footprint. Therefore, the use of lighter materials, such as carbon fiber composites, to replace heavier metals in cars is inevitable yet as of now few auto manufacturers implement composites in their cars. The high material, testing and development costs, much like the aerospace industry, have been prohibitive to widespread use of these materials but progress is being made in overcoming those challenges. The "trace" method, while initially intended for quasi-isotropic, aerospace grade carbon-fiber laminates, still yields reasonable, and correctable, results for types of laminates as well such as with woven fabrics and thermoplastic matrices, much of which are being used in these early stages of automotive composite development. Despite the varying use of materials, the "trace" method could potentially boost automotive composites in a similar way to the aerospace industry by reducing testing time and costs and perhaps even playing a role in establishing emerging simulations of these materials.

How can we change what it means to be a human? Products can be used that will allow for near-instantaneous communication with one’s friends and family wherever they are: and the newest devices do not have to be even carried around, as they can be worn instead. Wearable electronics are quickly becoming very popular, with 232.0 million wearable devices sold in 2015. This report provides an overview of current and developing wearable devices, investigates the characteristics of the average buyer for these different types of devices. Finally, marketing strategies are suggested. This work was completed in conjunction with a capstone project with Intel, where three objectives were achieved: First, a universal strain tester that could strain samples cyclically in a manner similar to the body was designed. This equipment was especially designed to be flexible in the testing conditions it could be exposed to, so samples could be tested at elevated temperatures or even underwater. Next, dogbone shaped samples for the testing of Young’s Modulus and elongation to failure were produced, and the cut quality of laser, water-jet, and die-cutting was compared in order to select the most defect-free method for reliable testing. Polydimethylsiloxane (PDMS) is a fantastic candidate material for wearable electronics, however there is some discrepancies in the literature—such as from Eleni et. al—about the impact of ultraviolet radiation on the mechanical properties. By conducting accelerated aging tests simulating up to five years exposure to the sun, it was determined that ultraviolet-induced cross-linking of the polymer chains does occur, leading to severe embrittlement (strain to failure reduced from 3.27 to 0.06 in some cases, reduction to approximately 0.21 on average). As simulated tests of possible usage conditions required strains of at least 0.50-0.70, a variety of solutions were suggested to reduce this embrittlement. This project can lead to standardization of wearables electronics testing methods for more reliable predictions about the device behavior, whether that device is a simple pedometer or something that allows the visually impaired to “see”, such as Toyota’s Blaid.

In injection molded plastic parts, knit lines occur where opposing streams of material fuse together while the mold cavity fills. When parts with knit lines experience external loading, the knit lines cause areas of mechanical weakness. This weakness is especially drastic in fiber-reinforced polymers due to an unfavorable orientation of fibers at the knit line. A possible way to reduce the impact of knit lines is to incorporate overflow tabs into the mold design. An overflow tab is a chamber attached to the mold cavity that provides an extra space for the end of material flow to occur. Research shows that overflow tabs improve the fiber orientation at the knit line, resulting in increased mechanical strength. The goal of this study is to utilize overflow tabs to optimize the knit line strength of nylon 6-6 that is 30% carbon fiber reinforced. In this project, an initial overflow tab is first designed. Then four modifications are made to the tab design, each altering a separate variable while holding the others constant. The design changes explored for the tab in this project include adding radii to the inlet, shifting the inlet location, increasing the inlet cross-sectional area by 50%, and increasing the tab chamber volume by 50%. Specimens were molded using the initial tab design and the modified tab designs. Testing for this experiment consists of three specimens of each type for three-point bending tests, and five specimens of each type for tensile tests. The material properties analyzed are the flexural modulus, flexural strength, tensile modulus, and tensile strength. From the testing, the tab with the 50% increased volume consistently yielded the highest results and showed large improvement from the initial tab design. However, the other three tab modifications either showed negative change or slight improvement from the initial tab design. Based on the results of this study, the overflow tab volume is the most beneficial design parameter to adjust.

Vitamins and minerals are, by definition, essential substances that are necessary for good health, and needed by every cell and organ to function appropriately. A deficiency of any one vitamin or mineral can be very serious. Although a very healthy diet rich in vegetables, fruits, and protein can provide sufficient amounts of most vitamins and minerals, many people do not consume an adequate diet. During pregnancy, there is an increased need for vitamins and minerals to promote a healthy pregnancy and a healthy baby. Prenatal supplements are intended to supplement a normal diet to ensure that adequate amounts of vitamins and minerals are consumed. The US Food and Drug Administration (FDA) has established Recommended Dietary Allowances for total vitamin/mineral intake from food and supplements, but they have not established recommendations for prenatal supplements. Therefore, there is a very wide variation in the content and quality of prenatal supplements. Many prenatal supplements contain only minimal levels of some vitamins and few or no minerals, in order to minimize cost and the number of pills. This results in insufficient vitamin/mineral supplementation for many women, and hence does not fully protect them or their children from pregnancy complications and health problems. Therefore, we have created our own set of recommendations for prenatal supplements. Our recommendations are based primarily on four sources: 1) FDA's Recommended Daily Allowances for pregnant women, which are estimated to meet the needs of 97.5% of healthy pregnant women. 2) FDA's Tolerable Upper Limit, which is the maximum amount of vitamins/minerals that can be safely consumed without any risk of health problems. 3) National Health and Nutrition Examination Survey (NHANES), which evaluates the average intake of vitamins and minerals by women ages 20-40 years in the US 4) Research studies on vitamin/mineral deficiencies or vitamin/mineral supplementation during pregnancy, and the effect on pregnancy, birth, and child health problems. In summary, the RDA establishes minimum recommended levels of vitamin/mineral intake from all sources, and the NHANES establishes the average intake from foods. The difference is what needs to be consumed in a supplement, on average. However, since people vary greatly in the quality of their diet, and since most vitamins and minerals have a high Tolerable Upper Limit, we generally recommend more than the difference between the RDA and the average NHANES. Vitamins generally have a larger Tolerable Upper Limit than do minerals. So, we recommend that prenatal vitamin/mineral supplements contain 100% of the RDA for most vitamins, and about 50% of the RDA for most minerals. However, based on additional research studies described below, in some cases we vary our recommendations from those averages.

The characteristics possessed by undergraduates who have enjoyed success in an intern position are defined. Through an interview process, four traits were identified: multitasking, strong team work understanding, an inquisitive nature, and application of a cross-disciplinary mindset. An exposition of how these four traits are employed to ensure success in an internship setting is then given. Finally, a personal account of a project with Intel is expounded upon. This project addressed the unoptimized characterization test time of an Intel package quality control process. It improved throughput by developing a parallel testing method by increasing package carrier capacity and utilizing simultaneous testing. The final design led to a 4x increase of throughput rate.