ME Projects – Spring 2025

Toyota Motor North America Research and Development (TMNA R&D) has been a leader in automotive innovation for over 50 years. The company is dedicated to advancing vehicle design, development, and mobility solutions that enhance customer experience. More recently, TMNA R&D has a new vision to include mobility solutions that improve accessibility for individuals with mobility challenges. They plan to achieve this vision by offering customers a more effective, sustainable, and affordable way to transport mobility devices.

The goal of this project was to “Develop a mobility transport accessory advertised, sold, serviced, financed, and available to all Toyota/Lexus customers.” [Gabriel Marciano]. More specifically, this project focused on improving the design of a lift mechanism for personal mobility aids, ensuring that individuals using powered wheelchairs or similar devices could safely and easily transport their equipment. The team worked on refining an initial prototype, which featured a lift and platform system attached to a trailer hitch. Enhancements included the development of a mechanism that allowed the mobility aid to be deployed from the towing position to either side, based on user preference, while also incorporating adjustable ground-level height. The final design aimed to create a user-friendly and efficient mobility accessory that could potentially be offered as a Toyota dealership accessory in the future.

Michigan State University

Team Members (left to right) 

Blake Christiansen
Lansing, Michigan

Alex Goolsby
Novi, Michigan

Ryden Khamo
Sterling Heights, Michigan

Maxwell Cheney
Milford, Michigan

Jacob Keegan
Plymouth, Michigan

Toyota Motor North
American Research
and Development

Project Sponsors

Gabriel Marciano
Plano, Texas

Todd Muck
Saline, Michigan

Becky Ward
Saline, Michigan

ME Faculty Advisor

Dr. Norbert Mueller

Consumers Energy is an investor-owned utility that provides natural gas and electricity to 6.7 million Michigan residents. As part of its commitment to achieving Net Zero carbon emissions— by 2040 in the electric sector and by 2050 in the natural gas sector—Consumers Energy is transitioning away from coal-fired power plants and investing in renewable energy. The company operates 13 hydroelectric plants, including the Hardy Dam, which has been providing clean and reliable energy for over a century.

This project assessed the feasibility of utilizing Hardy Dam’s hydroelectric power to produce green hydrogen for hard-to-abate industries such as heavy- duty transportation, cement manufacturing, and steel production. The team evaluated electrolyzer technologies, analyzed power availability, and examined hydrogen storage options, including underground salt caverns. Additionally, a high-level siting assessment and cost estimation were conducted. The results provided insights into the potential for reducing carbon emissions and supporting industrial customers in Michigan with their clean energy goals.

Michigan State University

Team Members (left to right) 

Waleed Munir
Rawalpindi, Pakistan

Mansoor Makki
Dubai, United Arab Emirates

Rishabh Ainapurapu
Dubai, United Arab Emirates

Hussain Ashkanani
Dubai, United Arab Emirates

Jack Jackson
Rochester Hills, Michigan

Consumers Energy

Project Sponsors

DeVon A. Washington
Jackson, Michigan

ME Faculty Advisor

Dr. André Bénard

Kautex Textron, a subsidiary of Textron Inc., is a global leader in automotive and industrial solutions, specializing in lightweight thermoplastic fuel systems, battery enclosures, and cleaning systems for autonomous vehicles. With over 5,000 employees and operations in more than 13 countries, Kautex has developed innovative technologies for automotive applications, including advanced composite materials used in electric vehicle (EV) components. Kautex is committed to advancing the use of composites in EV battery pack enclosures and underbody protection, ensuring high performance, cost efficiency, and sustainability. Their extensive research and validation facilities across the U.S., Canada, Europe, and Asia reinforce their ability to develop cutting-edge automotive solutions.

Our project focused on evaluating the cost and performance of various composite materials for potential use in Electric Vehicle (EV) applications, particularly in battery enclosures and underbody protection. The team conducted a comparative analysis of various glass- reinforced compression and injection molded grades of polypropylene (PP) and polyamide (PA), utilizing Computer-Aided Engineering (CAE) simulations to assess mechanical performance under specific load conditions to record peak impactor force load and deflection. By analyzing impact resistance and cost efficiency, we provided Kautex with data-driven insights to optimize material selection for future EV component designs.

The project also included a visit to Windsor, Ontario in late February to observe the manufacturing processes of Kautex’s products, which further informed our analysis of various material types.

Michigan State University

Team Members (left to right) 

Claire Jacka
Birmingham, Alabama

Sydney Dillon
Saline, Michigan

Noah Rockensuess
Buffalo, New York

Abigail Makowski
Ann Arbor, Michigan

Avery Powell
DeWitt, Michigan

Kautex Textron

Project Sponsors

Matthew Detrich
Troy, Michigan

ME Faculty Advisor

Dr. Haseung Chung

Munters has been a global leader in climate control since it was founded in 1955. Today, Munters operates in over 30 countries providing climate solutions for many industries ranging from food production to data center cooling. FoodTech is Munters’ agricultural sector, which focuses on energy efficient climate systems for chickens, cows, swine, and greenhouses. Did you know the effects of 15 minutes without proper climate regulation would be fatal for a chicken farm because of the extreme amount of heat they produce? This goes to show how essential Munters’ products are for livestock health and production.

Our project focuses on streamlining the validation process for various Munters’ products. The current validation process takes upwards of nine months due to the limitations of current test barns and weather restrictions. With our design, Munters can expedite this process, enabling it to get products on the market and into farms faster than ever. Our design features an innovative testing facility assessing performance and endurance on various fan sizes. Equipped with advanced control capabilities for air temperature, density, humidity and pressure, this facility will enable Munters to simulate a wide range of environmental conditions from its home base. Our design emphasizes feasibility, adaptability, and flexibility, ensuring that it can seamlessly meet current needs while accommodating future requirements. This system will aid Munters’ product development engineers for years to come.

Michigan State University

Team Members (left to right) 

Joe Dreon
Oakland Township, Michigan

Amelia Conatser
Ann Arbor, Michigan

Adam Martin
Rochester, Michigan

Anna Smith
Frankenmuth, Michigan

Chase Montour
Oakland Township, Michigan

Munters Corporation

Project Sponsors

Thomas Mohr
Lansing, Michigan

Tyler Quirk
Lansing, Michigan

ME Faculty Advisor

Dr. Yang Guo

Munters Lansing is a global leader in agriculture building ventilation. It specializes in designing, manufacturing, and validating industrial fans and shutters. Munters’ products cover the dairy, chicken, and green house spaces. Ventilation includes barn air extraction, fresh air intakes, humidity, and temperature control. Munters strives to enhance the security of consumer operations and production quality through innovative and efficient products, while minimizing the consumption of vital resources like energy and water.

The scope of this project was to design a 53’ container to test their industrial products. The intent of this project was to establish an environment that wasn’t limited by weather conditions or validation time, allowing for continuous durability testing throughout the year. The “validation” container design included features such as the ability to mount extraction fans on the vertical walls, maintenance of the optimal pressure difference to ensure the fans work under a load, and the incorporation of the electrical distribution and control systems. A key requirement for this container was that it must remain stationary at a fixed location during testing. It also had to be capable of being packed for transport between test sites while remaining fully compliant with DOT regulations.

Michigan State University

Team Members (left to right) 

Ian Burke
Ortonville, Michigan

Matthew Luxhoj
Rockford, Michigan

Joey Karr
Novi, Michigan

Zachary Wyrick
Waterford, Michigan

Ethan Darnall
Beverly Hills, Michigan

Munters Corporation

Project Sponsors

Mark Farone
Lansing, Michigan

Thomas Mohr
Lansing, Michigan

Tyler Quirk
Lansing, Michigan

ME Faculty Advisor

Dr. Yang Guo

Magliner, Inc. is one of the leaders in route distribution services and the manufacturing of aluminum hand trucks in the U.S. Founded in Standish, Michigan in 1947, Magliner has been committed to making the transportation of materials easy and safe. Its goal is to build products that customers can trust, and through the innovation and dedication of its team it ensures each one of its products upholds the “Made by Magliner” promise. Magliner is driven by the needs of its customers, and it will continue to make the process of moving products safer and more efficient for years to come.

Delivery drivers across the country use hand trucks to “stab” cases or packages to lift and transport them. The problem with this process is that drivers face a variety of environments and significant differences in packaging. Current hand trucks may work well on wood and tile floors but poor on asphalt, or they can easily stab cardboard but not plastic wrap. Our team was tasked to redesign the hand truck nose plate and create one that works well in all circumstances in addition to being easily serviced. This new nose plate reduces the effort needed to stab any load of products while working on any surface. Our design keeps the products stable while the operator is moving and easily enables them to remove the load. Furthermore, the new nose plate can be easily serviced, or even replaced, if it gets damaged during everyday use.

Michigan State University

Team Members (left to right) 

Tyler Hedden
Haslett, Michigan

Devin Bentley
Paw Paw, Michigan

Tyler Noel
Canton, Michigan

Kolby Wagoner
Coldwater, Michigan

Judson Wise
Auburn, Michigan

Ming Huang
Lacrosse, Wisconsin

Magliner, Inc.

Project Sponsors

Greg Ecker
Standish, Michigan

Andrew Lehman
Standish, Michigan

ME Faculty Advisor

Dr. Indrek Wichman

BONWRx, based in Lansing, Michigan, specializes in developing and manufacturing medical devices for spinal and nervous system treatments, including alternatives for vertebral augmentation procedures. The company offers a safer alternative to PMMA, a commonly used acrylic in bone cements with potential health risks, by using a proprietary elastomer. This biocompatible elastomer acts as a shock absorber for the spine, treating vertebral fractures that can lead to severe spinal deformity, back pain, immobility, and reduced quality of life. BONWRx’s mission is to alleviate these issues and reduce the need for additional medical procedures.

Our team was tasked with redesigning the VK100 system to enhance the dispensing handle’s usability and ergonomics. The redesign is to improve ease-of-use for medical professionals across specialties, while providing greater control during procedures. The new device uses a twisting motion to apply pressure (replacing the previous squeezing motion) and includes a release to stop elastomer flow when necessary. The new device ensures medical staff working long hours could perform their duties safely, comfortably, and effectively.

Michigan State University

Team Members (left to right) 

Joshua Machuca-Gonzalez
Jackson, Wyoming

Hanna Stabler
Chandler, Arizona

Shawn DeFina
Fenton, Michigan

Ashley Donbrock
Portland, Michigan

Nathan Zavsza
Clinton Township, Michigan

BONWRx

Project Sponsors

Ralph Carmichael
Lansing, Michigan

Rose Carmichael
Lansing, Michigan

ME Faculty Advisor

Dr. Seungik Baek

The IMPART Alliance initiative is an MSU-led program to train and support Michigan’s in-home Direct Care Workers (DCWs). Many Michiganders and their families care for their loved ones with the help and skills of DCWs; however, there is currently an urgent shortage of well-trained DCWs. IMPART Alliance strives to bridge the gap in DCW retention and recruitment by developing training curriculum and models, establishing effective protocols and procedures, providing professional training, and collating a database of DCWs based in Michigan. As part of the IMPART Alliance’s training program, its staff transport an assortment of training aids and other equipment to various locations around the state.

Our team’s project was to design a system that enabled IMPART Alliance staff to safely and easily load, transport, and unload four to five carts of equipment onto and from a cargo van provided by the MSU Motor Pool. To modify the carts as needed to fit into the van, we consulted with two other student teams tasked with the design and organization of the carts. An exterior commercial lift gate was installed onto the back of a Ford Transit van to lift and lower the carts, as the largest cart weighed nearly 150lbs. Inside the van, two sets of tracks attached to the floor guide the wheels of the carts and prevent lateral movement while the van was in motion. D-ring hardpoints are also present inside the van and provide attachment points for straps to further secure the carts. By working with the IMPART Alliance, the MSU Motor Pool, and the teams working on other aspects incorporated in this project, we were able to design an effective system that accommodates any IMPART Alliance staff who would operate it and enable them to safely carry out their training.

Michigan State University

Team Members (left to right) 

Cole Jeffery
Chicago, Illinois

Mohammad Alqaryouti
East Lansing, Michigan

Maxwell Cheng
West Bloomfield, Michigan

Alexander Le
Caledonia, Michigan

Sterling Mims
Okemos, Michigan

Kyle Taormina
Macomb, Michigan

MSU IMPART Alliance

Project Sponsors

William Resh
East Lansing, Michigan

ME Faculty Advisor

Dr. Galit Pelled

IMPART Alliance is a dedicated organization focused on improving the training and support of Direct Care Workers (DCW) who provide essential care for individuals in need. The organization works to enhance workforce development, training programs, and industry standards to ensure quality care. Through various initiatives, IMPART Alliance has aimed to make DCW training more efficient, accessible, and effective by addressing challenges such as resource organization and training logistics.

Our project focused on developing an improved system for organizing and transporting training equipment for DCW at offsite locations. We designed and built fully functional prototype carts and container systems to efficiently store and transport training materials, ensuring quick setup for different training modules. The project involved organizing materials into consumable, maintainable, and durable items while creating a tracking system to monitor inventory and maintenance needs. By optimizing storage solutions and enhancing mobility, our work contributed to a more structured and accessible training process, ultimately supporting the effectiveness of DCW education and workforce development.

Michigan State University

Team Members (left to right) 

Andrew Iaquaniello
Plymouth, Michigan

Monica Roberts
Troy, Michigan

Daniel Choroszucha
Grand Rapids, Michigan

Veronica Sellin
St. Joseph, Michigan

Ryan Bilsky
Washington, Michigan

MSU IMPART Alliance

Project Sponsors

William Resh
East Lansing, Michigan

ME Faculty Advisor

Dr. Galit Pelled

Eaton Corporation is a power management company that helps provide solutions through electrical, aerospace, hydraulic and vehicle products and service. Eaton Aerospace specializes in the development of aerospace products and technologies used in commercial, military, and business aviation. The Jackson Test Lab is fundamental in the testing of Eaton’s conveyance product line, providing top-of-the-line assessment through analysis of pressure, temperature, motion, and vibration data obtained during testing.

Eaton has a servo valve that operates an intensifier on a 2:1 ratio, which was used for applying pressure. The servo valve has two sides, sides a and b, which operate individually applying pressure. Because of this, when the pressure is lowered, the pistons lack the force to lower the pressure effectively on side b. The pressure over time can be seen in the figures to the right. Our goal was to create a dual-driven intensifier by utilizing the unused port on side b to drive both sides at the same time. This increases the control over lower pressures and increases the number of cycles the intensifier can run.

Michigan State University

Team Members (left to right) 

Elizabeth Ligi
Chelsea, Michigan

Emily Ligi
Chelsea, Michigan

Wenhao Jin
Zhoukou, Henan Province, China

Jessie Ernest
Northville, Michigan

Amos Amigon
Brooklyn, New York

MSU IMPART Alliance

Project Sponsors

William Resh
East Lansing, Michigan

ME Faculty Advisor

Dr. Elisa Toulson

Michigan AgrAbility provides critical assistance to enable people in the agricultural industry with an injury, illness, or disability to continue working. We are funded by the USDA through Michigan State University Extension and Easterseals MORC. Kami is a lavender farmer in Michigan with a disorder causing her foot bones to break. She contacted AgrAbility for assistance to relieve foot strain while pruning, weeding, and harvesting lavender. A previous capstone group designed a kneeling roller and at the end of the semester installed an electric drive motor.

The Kneeler Cart with chest strap enabled Kami to kneel with hand supports, as well as to lean forward while rolling along rows where she plants, harvests, prunes, and weeds a given crop. Working stooped over or kneeling and crawling is impossible for workers with back and lower extremity impairments who grow low fruits and vegetables. It requires good balance and strong legs to kneel and stand up unaided, along with eliminating the risk of falling. Rolling work seats help some farmers complete ground level tasks without crawling, but they must bend far over, straining their backs to reach the ground. Kami was unable to freely roll the cart from one place to another, so a neutral mechanism was implemented in order to achieve this. On top of the neutral addition, the Kneeler Cart has an improved drivetrain, which turns both wheels simultaneously via a live rear axle. A new steering mount is also included in this design upgrade so that turning the cart is more accessible and far easier. In order to make this a permanent design, the side supports, and overall stability of the cart were improved to make it far more robust, while still keeping it easy to recreate by future users.

Michigan State University

Team Members (left to right) 

Anthony Gibbons
Ann Arbor, Michigan

JP Nelson
Chicago, Illinois

Sean Flynn
Brighton, Michigan

Jacob Ervin
Grand Rapids, Michigan

Cade Smith
Portage, Michigan

Michigan AgrAbility

Project Sponsors

Ned Stoller
Lowell, Michigan

ME Faculty Advisor

Dr. Siva Nadimpalli

Bringing a production to life requires more than just vision – it demands craftsmanship, precision, and the right materials. The MSU Theatre Department Scene Shop crafts immersive scenic environments using wood, metal, and composites to create sets that captivate audiences. However, not all materials perform the same under the varying demands of live theatre. Choosing the right wood for a set piece means balancing strength, weight, and artistic finish. To enhance the selection process, we worked to develop a compact, portable, and digital hardness tester, enabling us to assess the strength of various materials before incorporating them into scene designs.

This project builds upon a previous capstone team’s work, which developed an initial mechanism to measure the force required to break, bend, or deform materials. The core structure was in place; however, the electronics needed additional programming and rewiring, while certain mechanical aspects required reworking. Our goal was to refine and redesign this device into a user-friendly tool for measuring hardness with precision. Integrating this technology into set design operations will optimize material selection, improve structural integrity, and enhance the efficiency of scene construction. This project is to provide a valuable tool for faculty and students in set construction, while also offering potential applications in theatre, film, and other industries that depend on wood hardness assessment.

Michigan State University

Team Members (left to right) 

Nathaniel Mcneilly
East Lansing, Michigan

Nathan Young
Saginaw, Michigan

Mariam Farran
Lawton, Michigan

Phillip Bereznicki
Chicago, Illinois

Nico Quirante
Okemos, Michigan

MSU Department of Theatre

Project Sponsors

Levi Galloway
East Lansing, Michigan

DJ Selmeyer
East Lansing, Michigan

Marc White
East Lansing, Michigan

ME Faculty Advisor

Dr. Guoming Zhu

MSU Adaptive Sports and Recreation Club is an inclusive club at MSU that promotes health, wellness, and teamwork through sports for individuals with physical disabilities. Piotr Pasik was inspired to start the program after seeing a lack of physical activity opportunities on campus for individuals with disabilities, and the club launched in 2014. Athletes have the opportunity to play a variety of sports in this club including boccia ball, wheelchair hockey, wheelchair rugby, hand-cycling, table tennis, and wheelchair tennis. Through the use of sports, the club strives to improve the physical health of its athletes as well as eliminate the societal stereotypes about disabilities.

This project is a continuation of a mobility scooter to provide Piotr (and many others who have cerebral palsy) with reliable transportation every day. The current two-wheel drive system performs well throughout most of the calendar year. However, once the winter weather starts, it is increasingly difficult to navigate the sidewalks, particularly with heavy snow fall. Implementing a synchronized three-wheel drive system would help to solve this problem. Currently, the front motor is burnt out and does not provide any help in the motion of the scooter. Implementing a new motor that synchs with the back wheel powertrain would provide much more torque, ensuring that Piotr can navigate the snow with no issues. In addition to this, engineering a new braking system will help in the winter months as well, because it is harder to brake on snow and ice.

Michigan State University

Team Members (left to right) 

Mitchell Fitzsimons
Richmond, Michigan

Rachel Zubrzycki
West Bloomfield, Michigan

Keegan Bretschneider
Howell, Michigan

Angela Wegrecki
West Bloomfield, Michigan

Nathan Huynh
Byron Center, Michigan

MSU Adaptive Sports and Recreation Club

Project Sponsors

Piotr Pasik
East Lansing, Michigan

ME Faculty Advisor

Dr. Guoming Zhu

The Michigan State University Department of Theatre is where excitement and intrigue are created through shows; including operas, plays, and other entertainment. Here is where many students and alumni, as well as other members of the community, can come to see new attention-grabbing creations through theatre. One of the most important aspects of putting these plays together is the creation of the scenery; this is how the audience is immersed into the stories they come to see. The scenery tells as much of the story as the characters and must be made with precision and care. This is the role of the MSU Department of Theatre Scene Shop faculty. They have the task of planning the many aspects that go into how the scenery is built, altered, and moved. The construction process warrants the use of a large number of raw materials and power tools, which continuously develop dust particulates that clutter their workspace and make it hard to continue their efforts.

Our team was tasked with the development of an adjustable dust collecting apparatus that could span large work areas, enabling the technical team to effortlessly collect the unwanted dust and debris from their work area. The system was integrated into the preexisting duct to provide a centralized waste receptacle. The designed arm enables any user to easily maneuver, position, and operate the dust collection system of the shop without having to bear the weight of the full system. It was designed as an overhead arm that enables the user to keep their hands on the workpiece while also keeping the system out of their path to maximize an efficient workflow.

Michigan State University

Team Members (left to right) 

David Benkes-Toth
Ann Arbor, Michigan

Stephen Moussiaux
Saint Clair Shores, Michigan

Dalton Dobyns
Moon Township, Pennsylvania

Brock Strebeck
Saint Joseph, Michigan

Paddy Toole
Elmhurst, Illinois

Hemanth Surapaneni
West Bloomfield, Michigan

MSU Department of Theatre

Project Sponsors

Levi Galloway
East Lansing, Michigan

DJ Selmeyer
East Lansing, Michigan

Marc White
East Lansing, Michigan

ME Faculty Advisor

Dr. Junlin Yuan

The Michigan State University Department of Mechanical Engineering has sponsored this project. The Human-Robot Collaborative Object Transport System is designed to improve coordinated transport of objects using AgileX LIMO robots controlled by human operators. The system integrates vibrotactile feedback vests, which will enable human operators to control the robots through shoulder movements while receiving real- time guidance.

Michigan State University

Team Members (left to right) 

Brian Cheladyn
Brighton, Michigan

Kieran Velasquez
Hartland, Michigan

Ben Kruk
Rochester Hills, Michigan

MSU Department
of Mechanical
Engineering

Project Sponsors

Vaibhav Srivastava
East Lansing, Michigan

ME Faculty Advisor

Dr. Ranjan Mukherjee

The MSU Broad Art Museum was established by Eli Broad, a Michigan State University alumnus, alongside his wife Edythe. Both lovers of the arts, they donated $26 million to the university in 2007 to build the Eli and Edythe Broad Art Museum. The 20,000-square-foot museum was opened five years later in 2012 (designed by the Pritzker Prize-winning architect Zaha Hadid) and placed perfectly on the edge of campus to face the surrounding community. The MSU Broad Art Museum boasts 10,000 works in its permanent collection, specifically focused on creating an inclusive environment by addressing implicit bias, systemic racism, and social inequalities. In addition to its permanent collection, the Broad Art Museum features local, national, and international artists through its rotating collection of exhibits.

When replacing exhibits in the museum, it is important to uphold the safe transportation of all artworks. This project is to continue the development of an advanced-level art transportation cart with a focus on developing an auxiliary A-frame top. The top must be collapsible for flat storage and easily assembled by any staff member. The modular A-frame also enables the cart to be used as an easel or display to reduce the number of times the art needs to be handled. With a strong focus on structural strength and an adjustable size to accommodate art pieces of various shapes and sizes, minimizing vibrations is also a critical consideration to eliminate potential damages during transit. The use of specific materials and structural design choices helped meet the criteria to deliver an effective prototype.

Michigan State University

Team Members (left to right) 

Lauren Spott
Schererville, Indiana

Max Doty
Midland, Michigan

Stephanie Glaspie
Rochester Hills, Michigan

Dominic Bednar
Macomb, Michigan

Emerson Voss
Plymouth, Michigan

MSU Broad Art Museum

Project Sponsors

Brian Kirchensteiner
East Lansing, Michigan

ME Faculty Advisor

Dr. Ricardo Mejia

The Department of Mechanical Engineering at MSU strives to approach difficult problems, enabling students to strengthen their engineering skills as they seek creative, feasible solutions. They also handle a variety of challenges, with the ultimate goal of learning, creating, and problem solving. The department provides education to undergraduate and graduate students through studies in automotive, aerospace, manufacturing, robotics, medical devices/artificial organs, and renewable energy. Leading-edge research is also conducted by professors who are involved in the program at Michigan State.

Our team was tasked with developing a chainsaw mounting system, with the main goal of creating a reliable and user-friendly sharpening method. The problem with the original design was that it was considered inefficient due to the loose grip of the fixture on the guide bar. As the file is used to sharpen the teeth, the pulling force would cause the chain saw to slip. This slipping posed a risk in terms of safety as well as damaging the blade and teeth. Our goal was to create a fixture that would prohibit all movement of the chainsaw with an easy and cost-effective setup.

This project was carried out in a three-step process: design, physical creation, and analysis. This was an iterative process, with the analysis including a proper selection of material, safety, and cost. The team was successful in creating a new design for the chainsaw fixture that holds the chainsaw more firmly, enabling the sharpening of the blade without movement.

Michigan State University

Team Members (left to right) 

Batu Akgun
Istanbul, Turkey

Oliver Horswill
Canton, Michigan

Jack Fisher
Bloomfield Hills, Michigan

Gunnar Carroll
Parma, Michigan

Kyle Deichmann
Grand Ledge, Michigan

David Stegehuis
Grand Rapids, Michigan

MSU Department
of Mechanical
Engineering
Project Sponsor

Project Sponsors

Jim Lang
Brighton, Michigan

ME Faculty Advisor

Dr. Ricardo Meija

Michigan State University takes pride in being green, both on and off the field. When it comes to food waste management, it is essential to be efficient, precise, and resourceful. For many years MSU has had a program to manage all food waste before it arrives at the consumers’ table, and dealing with any leftover products. The whole operation begins in the kitchen where food that is unfit to serve (scraps, etc.) is discarded in waste bins. Those bins are then taken to the MSU Surplus Store and Recycling Center, where they are sorted to remove unfit waste, dumped into larger containers, and hauled away to be processed. Besides taking action and processing tons of food waste, MSU’s Food Waste Management wants to educate both the public and workforce about the benefits of composting and correct disposal of food waste.

Despite active efforts to correctly dispose of food waste and to educate the public on proper items to dispose of, contaminants still end up in the food waste stream. Items such as kitchen utensils, latex gloves, plastic film, plastic bags, etc. can cause problems in the processing of this waste. Our project is to design a new pre-consumer quality control process to filter out unwanted materials, such as plastic and stainless steel, from the kitchen food waste bins in order to be acceptable at the campus anaerobic digester.

Michigan State University

Team Members (left to right) 

Ahmed Alsaegh
Al Qatif, Saudi Arabia

Nick Rogowski
Romeo, Michigan

Yulianna Duran
Orlando, Florida

Luca Boson
Grand Rapids, Michigan

Fatima Sharief
Holland, Michigan

Cade Smith
Cincinnati, Ohio

Student Life &
Engagement/MSU
Anaerobic Digestion
Research and
Education Center

Project Sponsors

Wei Liao
East Lansing, Michigan

William McConnell
East Lansing, Michigan

ME Faculty Advisor

Dr. Farhad Jaberi

The MSU Adaptive Sports & Recreation Club is a Registered Student Organization established in 2014. It was created to enable adult athletes with physical disabilities to participate in a handful of different activities. The program is open to athletes and able-bodied volunteers at the university and from the surrounding area. The program helps the athletes stay active and achieve their fitness goals, while building a community of athletes and volunteers. The club helps bring the lessons obtained through sports to the athletes (like self-efficacy) while educating the volunteers about the community and eliminating cultural stereotypes.

This project is the fourth phase of modifying the existing hockey roller sleds to increase athlete mobility. While previous phases have increased user control, there is still room for improvement in terms of speed and mobility. In their original state, the roller hockey sleds were very difficult to move on the Demonstration Hall Arena surface where they are primarily used. This required athletes in the program to exert significant effort without meaningful results in terms of movement. The new design prioritizes this in order to improve game flow, but more importantly to increase the inclusion of individuals with more involved physical disabilities.

Michigan State University

Team Members (left to right) 

Max Godin
Clinton Township, Michigan

Zachary Buchanan
Oxford, Michigan

Owen Heilman
Grandville, Michigan

Nicolas Sarafian
Northville, Michigan

Jon Hilton
Chesterfield, Michigan

MSU Adaptive Sports & Recreation Club

Project Sponsors

Piotr Pasik
East Lansing, Michigan

ME Faculty Advisor

Dr. Mohsen Zayernouri

The Michigan State Adaptive Sports & Recreation Club, located on campus, aims to provide an inclusive space where athletes can connect and form a supportive community. Open to both athletes with physical disabilities, as well as able-bodied volunteers, the club offers a variety of sports, including wheelchair basketball, wheelchair tennis, wheelchair floorball, and more. Since its inception, the club has grown significantly, expanding from just a few recreational sport options to competing in numerous tournaments against other colleges. It hosts open gym sessions on Monday and Thursday nights, inviting anyone to join and participate. The club plays a vital role in the community by offering athletes a chance to get active, build strength, and foster friendships with others.

Since fall of 2016, the MSU Adaptive Sports & Recreation Club has been collaborating with the MSU College of Engineering to support capstone projects for senior mechanical engineering students. The main purpose of this wheelchair is to enable ambulatory individuals with disabilities impacting arm function, to participate in team sports that require the use of a wheelchair. In a previous phase, a steering system was implemented that allows the chair to use brakes on either wheel via the lever. This semester, improvements were made to the wheelchair’s functionality by refining the steering system, making it easier to control and brake. Another goal was to increase compatibility with standard sport wheelchairs to simplify maintenance. This project was completed with the purpose of ease-of-use and accessibility for all people, and it was incredibly rewarding to help such an impactful group.

Michigan State University

Team Members (left to right) 

Joseph Dumais
Iron Mountain, Michigan

Nicholas Opolka
Iron Mountain, Michigan

Navid Hasan
Grand Rapids, Michigan

Brendan Cruz
Fenton, Michigan

Jacob Dumais
Iron Mountain, Michigan

MSU Adaptive Sports & Recreation Club

Project Sponsors

Piotr Pasik
East Lansing, Michigan

ME Faculty Advisor

Dr. Mohsen Zayernouri

T
he MSU Rocketry Team is a student engineering club that builds and competes against other college teams across America in the Space Port America Cup. Rocketry currently purchases fiberglass for its body tube; and it would like to convert to a lighter, stronger composite material. The club wants to start producing its own body tubes for competition rockets to increase performance, reduce costs, and optimize current designs. To complete this task a custom-tube winder must be manufactured to allow for repeatable, precise, and variable designs. To showcase the machines capabilities, a one- foot tube with a two-inch diameter will be made, enabling tuning of production, code, and material properties. It is designed to expand to accommodate tubes up to three feet long and six inches in diameter when ready. The goal of this project is to design a machine that can create tubes at smaller scales while enabling future expansion to larger diameters and longer lengths. This will enable the team to build custom rocket body tubes in-house, eliminating the need to purchase pre-made ones. A mandrel rotates while an epoxy-coated filament is wound onto it at precise angles using a sled driven by three stepper motors. Once wound, the assembly is shrink-wrapped and heated to cure the resin, forming a solid composite structure. The machine will offer versatility, precision, and efficiency as the team works to develop stronger, lightweight components for its rockets.

Michigan State University

Team Members (left to right) 

Connor Youngerman
Troy, Michigan

Dylan Miron
Port Huron, Michigan

Vinay Rao
Troy, Michigan

Kurt Kehren
Rochester, Michigan

Bobby Dessy
Rochester, Michigan

MSU Rocketry Team

Project Sponsors

Patton Allison
East Lansing, Michigan

ME Faculty Advisor

Dr. Thomas Pence

The MSU Formula Racing Team is a student- led organization at Michigan State University that designs, builds, and races in Formula SAE competitions nationally and internationally. Formula SAE was founded as a competition called Mini Indy in 1979. In 1981, its name was changed to Formula SAE, and a whole new journey started. It became one of the largest engineering competition series. The MSU Formula team proudly represents Michigan State University in Formula SAE competitions. MSU-FSAE is driven to push the boundaries of innovative automotive design. The MSU Formula Racing Team recently transitioned to the EV category and is focused on improving vehicle performance while promoting teamwork and competency.

For 30 years, Pratt Miller has driven innovation in racing and beyond, including the legendary Corvette Racing team. Now, with 300+ employees, it serves global clients in Motorsports, Defense, Mobility, and Innovation, and served as the technical/industrial advisor for this project.

The goal of this project was to design, build, and test a composite battery container for the MSU FSAE EV racecar that will meet the requirements of SAE electric racecar standards. The key advantage of using the new composite battery container is its lighter weight compared to the current one, thereby reducing the overall vehicle weight while maintaining high structural integrity. Our studies mainly focused on improving thermal management; making sure the cooling system was both effective and efficient; ensuring durability; and creating a light, reliable solution that integrates easily into the car’s chassis. As the MSU FSAE team transitions to EV, our main objective was not only to build a battery container but also to support future improvements as the team advances.

Michigan State University

Team Members (left to right) 

Jackson Larkin
Zeeland, Michigan

Arinc Kuloglu
Istanbul, Turkey

Huseyin Emir Canoglu
Ankara, Turkey

Nicholas Mercer
Woburn, Massachusetts

Gavin Lahousse
Ann Arbor, Michigan

Pratt Miller

Project Sponsors

Cameron Hesano
New Hudson, Michigan

ME Faculty Advisor

Dr. Gary Cloud

Cobra AERO is an advanced propulsion technology company that specializes in small, unmanned aircraft engines, such as drones and their related power systems. The company was established in 2012 as a branch to Cobra MOTO, using its skills of engine design and innovation to develop high-performance solutions for a variety of propulsion applications. The company initially focused on unmanned aerial vehicles (UAVs), although they have since expanded into other markets such as related controls and power electronics. They lean on partnerships with various companies such as Currawong Engineering and TWIG Power to continuously refine and deliver new propulsion systems. Cobra AERO has teamed with Jetfire Power, LLC to implement a new combustion system for their engine. The concept termed, Jetfire, is a product of Jetfire Power, LLC, which adds a pre-combustion chamber to the Cobra AERO engine, yielding a highly efficient, environmentally sustainable combustion engine.

This project was to redesign the cylinder heads for a 3-cylinder two-stroke engine to account for a rotary intake valve, as opposed to a poppet valve of previous Jetfire concepts. This will permit increased engine speeds and an aerodynamically favorable engine frontal area. The rotary valve is an integral part of the Jetfire ignition system that Cobra AERO is attempting to implement in its engine. The challenge of the rotary valve design was to conceptualize a method for adequately sealing the rotary shaft during combustion, while maintaining proper synchronization between the crankshaft and the Jetfire ignition system. Highlights will be the impact of this concept’s future combustion engine technology including compact size, enhancing power density and efficiency.

Michigan State University

Team Members (left to right) 

Alex Szumko
Ann Arbor, Michigan

Brandon Hineman
Macomb, Michigan

Kennedy Kullman
Shelby Twp., Michigan

Nour Darrag
Cairo, Egypt

Joshua Picciano
Livonia, Michigan

Cobra AERO and Jetfire Power, LLC

Project Sponsors

Harold Schock
East Lansing, Michigan

ME Faculty Advisor

Dr. Harold Schock

NASA is continuously pushing the boundaries of extraterrestrial exploration. New endeavors are always being developed and launched, encompassing goals in many fields of science. Some teams are focused on a surface composition of a celestial body, while others intend to study the object’s gravity and rotation. All missions, regardless of their scale, enable scientists to understand the galaxy better and push towards new discoveries. In recent years, one of NASA’s goals has been to create the smallest spacecrafts possible. One such small spacecraft could be used in a future mission to the surface of the asteroid Psyche. This asteroid has been the focus of many collaborations between NASA and universities across the country. Student projects have focused on many aspects of the mission to Psyche, including long-term simulations, sample collection, and even game designs that feature the object.

Psyche poses a unique challenge because it is one of the few remaining classes of solar system objects that has not been explored. Unlike many other objects in the solar system, it is likely composed largely of metals and is ellipsoid in shape rather than spherical. Many of the details of Psyche’s composition are still unknown. These factors make exploration challenging, because many techniques that have served other missions will not apply. NASA currently has a probe en route to Psyche, which will arrive sometime in 2029 and will orbit the asteroid to collect data. In the future, scientists and engineers may propose the launch of a second mission that would land on the asteroid’s surface. Our team developed ideas for a power source for that mission. We selected a renewable energy generation method that would provide enough power for the duration of the mission and brainstormed a method for excess energy to be stored.

Michigan State University

Team Members (left to right) 

Ari Mustafaraj
Troy, Michigan

Chase Marcath
Macomb, Michigan

Renee Kinsler
Holland, Michigan

Daniel Krahn
Imlay City, Michigan

Mallory Brooks
Saginaw, Michigan

NASA Psyche Mission

Project Sponsors

Cassie Bowman
Tempe, Arizona

ME Faculty Advisor

Dr. Hamidreza Modares

Black walnut trees present an opportunity as an agroforestry food source, but their exceptionally hard shells make accessing the edible kernel difficult. The most effective way to access the edible portions is to crush open the hard walnut, which results in an intermixed assortment of highly variable sized portions of shells and edible “meats”. Due to the significant overlap in fragment size, traditional sorting methods struggle to efficiently separate the edible portions from the shell.

For this project, the goal was to develop an effective and feasible small-scale system to sort black walnut shell fragments from the edible insides. Our concept is based on hardness principles: a walnut shell resists needle penetration, whereas the meat resistance is minimal. By applying a controlled force, the penetration depth or resistance determines the classification of walnut fragments. Sponsored by the Michigan Nut & Fruit Growers Association, this project presented an opportunity to apply mechanical design principles to a real-world agricultural challenge. Our project is to enhance processing efficiency, minimize waste, and support sustainable food production by creating an accessible and efficient sorting solution. The final design provides an innovative approach tailored to small-scale users who currently lack practical affordable separation methods.

Michigan State University

Team Members (left to right) 

Larissa Tacaoca Honda
São Paulo, Brazil

Kaitlyn Heffelbower
Woodland, Michigan

Aida Soltanian
San Diego, California

Genna Lebster
Holland, Michigan

Charlotte Neu
Hartland, Michigan

Michigan Nut & Fruit Growers Association

Project Sponsors

Dan Guyer
East Lansing, Michigan

Dennis Strahle
Eagle, Michigan

ME Faculty Advisor

Dr. Rebecca Anthony

The MSU Bikes Service Center’s mission is to help people enjoy bicycling on campus and beyond by offering everything from new bikes, used bikes, rentals, parts, accessories, to repairs. At Michigan State University, there is an abundance of around 1,000-1,500 bikes being abandoned each year, which MSU Bikes can access. This makes them a great potential resource for parts that can be modified to function as an affordable lower limb prosthetic. Modern prosthetics, though effective, are not always a feasible option due to their high costs and complex technologies. Currently, 90% of people in third world countries who are missing limbs do not have prosthetics to help them in their daily lives. Working with the MSU Bikes Service Center, sponsor Ben Hogan, a Certified Prosthetist Orthotist at Mary Free Bed hospital and former student at MSU Bikes, has come up with the idea of utilizing many of the abandoned bikes found around the world as parts for affordable prosthetics. Ben considered many of the challenges in developing countries and wanted to find a way to produce prosthetics cheaper and more accessibly. Ben addressed these challenging factors by creating a functioning prototype made entirely from bicycle parts and wanted us to explore and refine the idea further.

Our project was to assemble another prototype using the original design of a below-the-knee prosthetic from a bike, following steps to ensure it can be made with ease. We modified the design when necessary to make it easier to produce with commonly available tools. We looked at the variability of the fit and the durability of the prosthetic under constant load. We also worked with a volunteer client to perfect the fit of the design and perform analysis on the prosthetic in a real-world environment. The goals for our design work included something more functional, lightweight, and easy to build and adjust.

Michigan State University

Team Members (left to right) 

Sydney Bush
Fowlerville, Michigan

Corey Smith
Portland, Michigan

Abigail Yager
Riverside, Illinois

Brenna Marsin
Harper Woods, Michigan

Jordyn Porter
Park Ridge, Illinois

MSU Bikes Service Center

Project Sponsors

Ben Hogan
Saginaw, Michigan

Bill McConnell
East Lansing, Michigan

Tim Potter
East Lansing, Michigan

ME Faculty Advisor

Dr. Lik Chuan Lee

The Michigan State University Solar Racing Team is a student-led engineering team focused on creating solar-powered race cars from scratch. Through the team, young engineers gain experience by engineering an automobile. Students design, assemble, and manufacture parts through the use of welding, milling, lathing, and other techniques, resulting in unique experiences gained by applying knowledge from their engineering courses to real-world issues. Their first solar-powered vehicle was created in 2010, and they have produced six new models since, including the most recent one called “Cynisca.” This car is set to compete in the Single Occupant Vehicle class at the Formula Sun Grand Prix later this year.

This project is an exploration for the next iteration, a new three-wheel suspension setup that mainly focuses on the design of the single rear wheel suspension containing the hub motor. The suspension previously consisted of a double wishbone set of control arms on all four wheels, where the arms regulated the motion of the wheels and a coilover connected the lower control arm to the chassis to absorb bumps and improve handling. With the new single rear wheel suspension, the vehicle’s weight, cost of manufacturing, and packaging space were all expected to decrease. Meanwhile, ease of machinability, handling, and reliability are expected to increase as a result of using fewer than half as many parts. This all contributes towards creating a more efficiently run and sustainably produced car.

Michigan State University

Team Members (left to right) 

Robert Stowe
Highland, Michigan

Manbir Chadha
Ann Arbor, Michigan

Egemen Keskin
Izmir, Turkey

Connor Whitaker
Macomb, Michigan

Jash Modi
Ahmedabad, India

MSU Solar Racing Team

Project Sponsors

Rachel Schneck
East Lansing, Michigan

ME Faculty Advisor

Dr. Brian Feeny

Founded in 1908, General Motors (GM) is a major American automotive company based in Detroit, Michigan. As one of the world’s largest car manufacturers, GM produces a diverse range of vehicles under popular brands like Chevrolet, GMC, Cadillac, and Buick. With a strong global footprint, the company offers everything from electric vehicles to trucks and SUVs. In recent years, GM has increasingly focused on advancing electric vehicle technology, autonomous driving, and sustainability efforts by positioning itself at the forefront of the future of transportation. Additionally, GM has made significant investments in technology and innovation, including partnerships in the development of self-driving vehicles and smart mobility solutions. The company also places a strong emphasis on corporate social responsibility, aiming to reduce its environmental impact while enhancing the safety and efficiency of its products.

Our team designed and manufactured a multi-disc basket clutch system for Michigan State University’s Baja vehicle which is a critical component commonly used in off-road vehicles. The clutch features a pack of multiple friction discs and steel plates that engage and disengage to transfer power from the engine to the front wheels, offering rapid disconnection when needed. This system not only enables the vehicle to always be in the optimal drivetrain configuration for varying terrain but also limits the forces through the chain powering the front wheels, reducing wear on key components. By providing quick, efficient power management, our design enhances both performance and durability, ensuring that the Baja vehicle can adapt to any given scenario with minimal mechanical stress.

Michigan State University

Team Members (left to right) 

Max Fried
Farmington Hills, Michigan

Elijah Carey
Hemlock, Michigan

Kody Simmons
Midland, Michigan

Kylie Keller
Kentwood, Michigan

Gabe Guter
Gaylord, Michigan

General Motors

Project Sponsors

Evan Boyers
Detroit, Michigan

Thomas Dionne
Detroit, Michigan

ME Faculty Advisor

Dr. Ahmed Naguib

Baja SAE is a student-led competition where teams design, build, and test a single-seat, all-terrain vehicle. Students on the MSU Baja Racing team gain hands-on experience ranging from engineering and design to testing and competition, with students working together to meet the competition’s rules. Since the 1970s, MSU Baja Racing students have dedicated long hours in both the machining shop and computer labs to develop innovative vehicles. Every year, the team travels to global competitions where over 80 teams compete in various challenges with their custom vehicles.

The goal of this project was to research, design, test, and manufacture custom brake calipers for the next MSU Baja car, while maintaining or improving braking power and packaging while also reducing the size, weight, and cost of the calipers. Prior to this project, the MSU Baja Racing team used the Wilwood PS1 Caliper. The PS1 is a lightweight, compact brake caliper made from cast aluminum with two stainless steel deep cup pistons, internal fluid passages, and a low-profile design. Despite these advantages, the size, weight, and packaging of the Wilwood PS1 Calipers cannot be customized, making them undesirable for MSU Baja. Given the extreme use case of these calipers (racing), the custom calipers were designed for easy serviceability, enabling quick replacement of the brake pad. Reliability was a top priority, as faulty brakes pose significant safety risks. Designing and manufacturing custom calipers from CNC-milled aluminum addressed these issues and achieved improvements.

Michigan State University

Team Members (left to right) 

Sydney Agius
Grosse Pointe, Michigan

Justin Tyack
Rochester, Michigan

Elizabeth Grant
Northville, Michigan

Robert Crouse
Brighton, Michigan

Matthew Osborn
Milan, Michigan

MSU Baja Racing

Project Sponsors

Phil Hill
East Lansing, Michigan

ME Faculty Advisor

Dr. Neil Wright