Senior Design

Senior Capstone Design is one of the most important courses in the four-year curriculum. Students work beyond the traditional classroom setting to apply technical knowledge to actual engineering problems.

Teams are graded on their requirements analyses, feasibility studies, financial analyses, system designs, engineering drawings, prototype hardware, computer programs, presentations, demonstrations and reports. The experience helps students bridge the gap between their academic and professional careers by exposing them to realistic design processes, teamwork and expectations of practicing engineers.

Teams meet periodically with their client to review designs and provide written and oral progress reports. At the end of each semester, teams give a final presentation and write a design report. Evaluation is based on individual and team performance.

Senior Capstone Design provides these development facilities for the project teams. 

  • Projects Lab (LN-G111)
  • Tech Lab (EB-A4)
  • Vehicle Lab (EB-A3)
  • Electric Vehicle Lab (EB-D1)
  • Special Projects Lab (EB-A8)

The Projects Lab has a diverse array of benchtop equipment, which is assigned to individual teams as needed. The Tech Lab has a 3D digitizer, two 3-D printers, and several surface-mount technology soldering systems. The Vehicle Lab has innumerable automotive tools, including a TIG welder, and is home to the SAE Supermileage and MiniBaja project teams. The electric vehicle lab is home to the SAE Formula Electric vehicle. The Special Projects Lab is used for larger projects that will not fit into the Projects Lab. 

2019/2020 Senior Design Projects 

  • SAE Baja frame and suspension

    The students will complete a full frame that meets the competition frame requirements and has a combined safety factor of more than two. The frame and main suspension members must also have a combined weight that is 10% less than last year’s design to ensure we are moving forward with the latest design iteration of the 2019-2020 vehicle.

    Sponsor: SAE Baja

  • SAE Baja powertrain and electronics

    The gear box was over designed in 2017 to prove concept along with being able to handle the additional weight of the current frame. The gear box must be redesigned to accommodate the redesign of the frame and to reduce weight of the overall Baja vehicle. Design a dashboard to display the metrics of the engine in order to ensure the engine is performing to its potential HP. This will give the information to the team that is needed for testing and efficiency.

    Sponsor: SAE Baja

  • Aerodynamic Downforce FSAE Front Wing

    The purpose is to create an interchangeable, snap-on, front-mounted aerodynamic wing on the existing formula internal combustion vehicles currently owned and operated by the Society of Automotive Engineers (SAE) chapter at Binghamton University. It must meet all requirements of the Formula SAE competition rule book and must be designed with efficiency as the main objective. 

    Sponsor: SAE Baja

  • SAE Supermileage drive train and powertrain

    Test and run an electric fuel injection system to achieve 1,000 miles per gallon or more. Engine and driver access panels from the 2018-2019 monocoque chassis shall be redesigned to fit seamlessly with the rest of the chassis. The monocoque chassis shall be inspected, and the existing body and wheels shall be optimized (ie polish, relube, etc.) and repaired if necessary. 
    The vehicle shall be SAE Supermileage competition ready by the end of March 2020.

    Sponsor: SAE Supermileage 

  • Hyperloop: braking

    Hyperloop pod braking mechanism to be redesigned to meet safety requirements imposed by SpaceX. Validation, prototyping and testing is required for the Fall semester.

    Sponsor: Hyperloop (Competition)

  • Hyperloop: stability and control

    Hyperloop pod stability and control system to be designed, manufactured and tested to meet requirements impowed by SpaceX. Vehicle dynamics modeling is required for the Fall semester.

    Sponsor: Hyperloop (Competition)

  • Hyperloop propulsion

    Hyperloop propulsion system to be designed, manufactured and implemented to meet the requirements imposed by SpaceX.

    Sponsor: Hyperloop (Competition)

  • Breathing Monitors powered by breathing motion

    This project seeks a design that can lay on a person’s belly and can monitor breathing rhythm and communicate unusual rhythm through a wireless device. This capability becomes essential for patients who need continuous health monitoring. As this information is critical, the goal of this project is to investigate the feasibility of converting breathing motion to power breathing monitors.

    Sponsor: Sherry Towfighian (internal)

  • RACECAR Upgrade for Autonomous Driving with Aggressive Maneuvers

    The RACECAR system is a powerful platform for robotics research and education. RACECAR is built upon a powerful 1/10-scale car. This project aims to upgrade and improve the performance of the independently controlled bake system, telemetry system (speed, steering angle, and force, etc.) for all four wheels, which enables the precise control of the aggressive maneuvers for autonomous driving.

    Sponsor: Kaiyan Yu (internal)

  • Mini LCD 3D Printer

    Design and fabrication of a compact building plate and resin vat system for an Anycubic LCD 3D printer.

    Sponsor: Pu Zhang (internal)

  • Movie Projector Spinner

    A project to create an apparatus for an installation piece, including a system, which would rotate (spin) the image projected by the camera at 40 rpm.

    Sponsor: Tomonari Nishikawa (internal)

  • Accessories for Bolex 16mm Movie Camera

    A project to create two accessories for a Bolex camera: a video assist that displays the view from the viewfinder on a monitor and a hand-crank that allows an operator to expose and advance the film manually.

    Sponsor: Tomonari Nishikawa (internal)

  • Vacuum chamber for measuring MEMS vibration

    This project involves the design, assembly and verification testing of a vacuum chamber for measuring the dynamic response of small MEMS devices.

    Sponsor: Sherry Towfighian, Ron Miles (internal)

  • Kincky hose

    Firehose when kinked reduces the water flow through the hoseline. This phenomenon also occurs in common garden hose, where it is merely annoying. Unfortunately, during an emergency situation in which fire hoses are used, the result can be disastrous: a reduction in gallons per minute (gpm) will delay extinguishing the fire which, in turn, threatens the lives of those trapped in the burning building, as well as endangering firefighters. Each kink can reduce the GPM through the nozzle by as much as 50%, and three or more kinks might entirely eliminate water flow. The current method used to prevent these kinks is to assign one or more firefighters to ‘chase the kinks’ (i.e.: continually check the lines and move/adjust them to prevent them from kinking). This is not ideal as it decreases the number of firefighters available to fight the fire. The kinks are most frequently caused when the hoseline turns a corner inside a building, gets caught under a doorframe or other object, wraps a stairwell bend too tightly, or isn’t ‘flaked out’ (pulled off the truck) correctly.

    This problem can occur in attack hoselines that are brought inside the fire building (typically 1.75” to 2.5” in diameter depending on strategic requirements) and supply hoses (3” to 5” in diameter). Attack hoses require constant maneuverability, as they are rapidly moved throughout the building during the fire attack, while supply hoses typically remain in a static position after being charged (larger diameter supply hoses are extremely difficult to move when filled with water).

    Sponsor: Roy McGrann (internal)

  • 2-Degree-of-freedom flight simulator

    Project is aimed at designing and building a flight simulator equipped with 2 DOF motion system (pitch and roll), visual system (1 or 2 channel) and a set of basic control inceptors (stick, throttle control and pedals). Intended use of the simulator is to conduct basic pilot-in-the-loop light control task simulations.

    Sponsor: Kirill Zaychik (internal)

  • 'Well Hung' - The Collapsible Hanger for the Consummate Traveler

    Countless business professionals travel daily around the globe and pack suitcases with their essentials. Although the clunky shape of a hanger prohibits ease of transport and there is often hesitation to use hotel hangers, why can’t an alternative product be developed that fosters compactness, durability, convenience, and style for the consummate smart traveler?

    Sponsor: David Kahan

  • CubeSat deorbiting

    Cubesats are becoming increasingly more popular with over 3,500 planned launches in the next year. The objective of this project is to design a mechanism that will function properly in space and deorbit by increasing drag to decrease the amount of orbital debris in lower earth orbit.

    Sponsor: Thomas Hurley

  • Thermodynamics bench

    Sponsor: Paul Chiarot (internal)

  • Mini Furnace

    Design and build a mini-furnace, with viewing windows, for testing materials under vacuum or gaseous environments with controlled heating/cooling. This oven will be used for testing bonding methods/materials (sintering, soldering, epoxy curing) for electronic packages and gain visual information on material response to various conditions.

    Sponsor: Universal Instrument (external)

  • Alternate Heat Exchanger Plenum

    Design and fabricate a 3D printed air-cooled heat exchanger to replace a dip-brazed air-cooled plenum made woth aluminium fin stock.

    Sponsor: BAE (external)

  • Center for Technology and Innovation: Design and Structural Analysis of an "Innovation" Sculpture

    The goal for this project is to perform the structural design and analysis of a large rooftop sculpture for TechWorks! The sculpture will be seen from multiple points around Binghamton and will need to be strong enough to withstand wind forces and other environmental conditions.

    Sponsor: TechWorks (external)

  • Hydropower for Nuthatch Hollow

    Enhancing WCP29's hydro-power generation project by designing a damning system for the intake pipe allowing water to collect and store during daytime, then release at nighttime for concentrated flow. An outtake pipe connection shall be designed, flex pipe shall be replaced with smooth pipe, and pipe connections shall be upgraded.

    Sponsor: Nuthatch Hollow center

  • ASME Human powered vehicle

    Human powered transportation is an engineering solution to problems found in both developed and underdeveloped areas of the world. Often times, the only type of transportation available is human powered. Dense urban areas with growing populations are in need of a way to reduce emissions and ease congestion. The Human Powered Vehicle capstone project challenges students to design and build a device to solve such issues. The project requires numerous mechanical design principles and optimizations for efficiency.

    Sponsor: ASME HPVC (competition)

  • Sidewall Heating and Cooling of Cylindrical Lithium Ion Cells for Electric Vehicle Applications

    Thermal management of cylindrical li-ion cells in electric and hybrid electric vehicle battery packs is of critical importance to pack performance, lifetime, and safety. Students will design, build, and use a test fixture that allows them to evaluate the effectiveness of various sidewall cell heating and cooling methods for battery packs in electric and hybrid electric vehicles.

    Sponsor: BAE (external)

  • Busbar Cooling of Cylindrical Lithium Ion Cells for Electric Vehicle Applications

    Thermal management of cylindrical li-ion cells in electric and hybrid electric vehicle battery packs is of critical importance to pack performance, lifetime, and safety. Students will design, build, and use a test fixture that allows them to evaluate the effectiveness of various busbar cooling methods for battery packs in electric and hybrid electric vehicles.

    Sponsor: BAE (external)

  • Mobile Art Studio 

    The art department would like to have a mobile art studio to take to various locations around the country. This studio would be built inside a commercially available foldable building (https://www.tenfoldengineering.com). The appropriate ten-fold building would be modified to include a woodworking shop, metalworking shop, ceramic studio, and metal casting facility. The suitable ten-fold building must be selected. Equipment to be included in the studio must be specified. All power for the equipment must be provided without connection to the grid.
    A final structural scale model must be fabricated using 3-D printing 

    Sponsor: Roy McGrann (internal)

  • Data center I

    Sponsor: Bahgat Sammakia (internal)

  • Data center II
    Sponsor: Bahgat Sammakia (internal)
  • Motorised Mobility Assist Device

    For this senior design project, the primary objective is to create a motorized device which would assist recovering patients with lower limb impairments to move about, i.e. improve their mobility in urban environment. The team would have to design the concept from scratch, while being allowed to incorporate design ideas of the existing motorized mobility devices, such as scooters, bicycles, wheel chairs, etc. Students will have to build the frame and steering mechanism. It is allowed to use off-the-shelf products for the propulsion mechanism. The original concept idea for MMAD involves usage of the electric motor and a battery pack.

    Sponsor: Kirill Zaychik (internal)