Department - Author 1

Industrial and Manufacturing Engineering Department

Degree Name - Author 1

BS in Industrial Engineering



Primary Advisor

Daniel Waldorf


The purpose of this project is to design and manufacture an improved upper control arm for a 1988-1998 Chevrolet K2500 truck. This component controls the suspension of a vehicle and will be redesigned to improve the many shortcomings of the current design. The objectives of this project were met by redesigning the stock upper control arm, designing and manufacturing a weld fixture, manufacturing a prototype component, and performing a cost analysis. This component was designed to improve performance, reliability, serviceability and strength while maximizing manufacturability. The fixture and upper control arm were manufactured using computer aided design, CNC methods and welding. Successful prototype fabrication has resulted in the evaluation of small, medium, and large production volumes. Recommendations have been made for the future direction of this component.