In summary, the Design and Manufacturing Clinic implements from 35 to 40 projects each year. Each project is different. Project teams usually are composed of 3, 4 or 5 students. We charge industry sponsors $3000 per project for a complete/final design project. Projects that involve conceptualization are included in one credit hour courses and are charged a fee of $1500. There are about 65 students engaged in clinic-sponsored projects each semester. On average 14 faculty members will mentor these. Since the clinic began operation in 1996 we have implemented over 120 different projects with about 50 companies. The following lists some of our recent experience with projects for local companies. Aerospace Company The nose cones on the propeller housings are manually polished as a part of the fabrication process. This project examined and developed techniques to do this automatically. This included systems designed by the student teams as well as commercially available systems that could be modified for this application. Press Manufacturer A local company manufacturers large presses. Part of the fabrication process requires specialty weld techniques. This project examined the strength of the welds as a function of weld geometry. Both theoretical and experimental evaluations were performed. The results from this project should save the company over $5000 per large press fabricated. HVAC Manufacturer A manufacturing work cell is required to be at an elevated position immediately after a high temperature drying operation. A student team acquired data during various stages of the operation to determine the temperature and working conditions. Concepts (HVAC) were developed to improve the working conditions. Medical Products Company The development of concepts for improving the performance of surgical devices. This was the first of a three-semester sequence, which concentrated on conceptualization. Manufactured Homes Manufactured homes have unique challenges in the transportation and placement of units in the field. The company uses a roll-off process at the site rather than cranes. The student team developed better methods for improving the efficiency and safety of the process. First Tier Supplier A student team evaluated the current method of positioning carpet on a mold during heating. The accurate positioning of pneumatic cylinders was designed and developed. University Service The development of the neighborhood close to a grade school involved the investigation of the use of a house/property adjacent to the school. A student team worked with the neighborhood association, school personnel and UD administration to develop and implement a plan. The first phase included the decision of demolishing the house on the property and the development of concepts for the property. Two student teams worked independently to present concepts. Large Vehicle Frame Supplier A local company manufacturers specialty aluminum parts and assemblies for the transportation industry. One process involves the bending of aluminum channels. Some channel designs have a high reject rate because of fracture of the channel. A student team investigated the process from extrusion to forming. Extensive testing was performed to determine stress and strains. Many improvements were recommended which has improved the success rate for this process. Conveyor Manufacturer A conveyor system manufactured by a local company has not been redesigned since the 1950’s. Because of the reliability and cost advantage of this system it has been seen increased sales demand over the past few years. Along with this has come increased operating demands, such as tighter turns and steeper up and down slopes. This has resulted in higher forces and binding of a chain. A student team examined the power, speed and force requirements. This resulted in extensive tests and design improvements. University Service ETHOS, Engineers in Technical, Humanitarian Opportunities of Service learning was a project undertaken by a multi-disciplinary development team. The students developed a plan, using the product realization process (PRP) to promote student involvement in developing countries while students at UD. This would be similar to Co-op but focused on service learning. Instrument Manufacturer A need existed to protect fittings and fiber optic cables during autoclave cleaning. The student team researched materials, generated concepts and built prototypes for a sealing cap that is now being marketed by the company. Component Manufacturer Compressors need to be leak tested during assembly. A new laboratory and assembly test method was designed and developed to produce results that would show if leaks were occurring. Insulation Fabricator Metal straps and clips used to install insulation on pipes are manufactured and assembled by hand. This labor-intensive operation has been the subject of conceptual, detailed and final designs for three consecutive semesters. This semester the focus was on conceptual designs. Engine Manufacturer A student team was commissioned to improve the inspection of the proper placement of piston rings during internal combustion engine assembly. The team investigated mechanical and optical methods. Automotive Supplier The fabrication of molds for carpet forming requires the use of epoxy forms. The mixing of hardener and resins is done manually. The student team developed concepts to perform this automatically. Aluminum Frame Manufacturer The aluminum frames on the windows for school busses occasionally may lose their seal. New frame and latching methods were conceptualized.