College - Author 1

College of Engineering

Department - Author 1

Mechanical Engineering Department

Degree Name - Author 1

BS in Mechanical Engineering



Primary Advisor

Sarah Harding


This Final Design Review (FDR) report outlines the senior design project that was conducted by a team of four mechanical engineering students at California Polytechnic State University-San Luis Obispo for ERG Materials and Aerospace Corporation. The goal of this project was to design displays that showcase the properties of ERG’s Duocel® foam at tradeshows and client meetings. To better understand the needs of our sponsor, the team researched Duocel®’s capabilities, related technologies, and relevant standards and regulations. With this information, we further defined the problem by creating a problem statement and a set of engineering specifications through a Quality Function Deployment (QFD) process. The first step we took in tackling our design challenge was to determine which properties of the Duocel® foam would be suitable for table-top displays and be most beneficial to our sponsor. It was found that the thermal and fluid flow properties of the foam were most important to our sponsor. Though a series of ideation and idea refinement processes the team designed a Flow Control Display and a Thermal Conductivity Display. The Flow Control Display demonstrates the varying flow resistance of different porosity Duocel® foams using a manual air-pump system. The Thermal Conductivity Display is comprised of heating and cooling elements that demonstrate the heat dissipation ability of Duocel® foam. To verify the feasibility of our designs, we built concept prototypes. With sponsor approval, the team moved forward with the Flow Control Display and redesign the Thermal Conductivity Display. The team created detailed designs for both displays, complete with engineering drawings and wiring diagrams. Additionally, manufacturing plans, testing procedures, and structural prototypes were developed for each design. Confirmation prototypes were manufactured based on the final designs on staggered timelines. First, the Flow Control Display was assembled and tested. The test results revealed that this display did not function as intended. The team proceeded to troubleshoot the display and determined that the functionality issues were a result of insufficient velocity of air flow. Next, the Thermal Conductivity Display was manufactured and calibrated. Once it was satisfactorily assembled, the display was tested and met all the engineering specifications identified at the beginning of the project. This document contains the research, ideation processes, design decisions, design outcomes, manufacturing processes, test results, and project management associated with this senior project.