Goodrich Aerospace - Brake Adjuster Project

Students were responsible for creating a new design with improved mechanical properties. The purpose of this device was to, (1) compensate for wear of the aircraft brake stack, and (2) pull away from the brake stack a set amount after every brake event.

The project started with a thorough survey of existing literature and patents. The students then came up with over 30 unique conceptual solutions to the problem. Various forms of analogies, brainstorming techniques, and Delphi methods were used to search the design space. Through design reviews and feedback from the sponsors, this list was narrowed down to 5 that were considered in detail.




These 5 concepts were analyzed in great detail and detailed dimensions were found for them. After significant discussion, internally and with the sponsor, these 5 were down selected to a single final design.

A physical prototype was created and instrumented to verify the force needed to actuate the adjustment mechanism and the amount of pull back. The prototype was instrumental in thinking up several variations of the initial design. This project was an outstanding example of our course philosophies of creative design, industrially relevant projects, physical prototyping, use of quality metrics, and testing.

Honda of America – Paint Mask Project

Students from the departments of Industrial Systems and Mechanical Engineering were asked investigate paint overspray, improve quality, reduce manpower, and address ergonomics in the production of two-toned dashboards. This was a complex process involving paint masking, demasking, attachment of hardware, ultrasonic welding of vents, and inspection.

One of the results of this project was the design of a new paint mask. The initial paint mask did not adhere to the dashboard and was identified as the major quality issue.

A prototype mask was created and was used to assess improved quality. This lead to improved quality, reduced rework, and less work in process.