2013-14 Senior Design Projects

Sponsor

The Nonwovens Institute

Team Members

Mitchell Bost, Monet Freeman, Kyle Joynes, Tyler Reiss

Project Description

New methods are sought to improve fabric-to-fabric bonding that do not rely on existing common methods such as stitching, sonic welding, or melt processes. The ability to join fabrics, particularly nonwoven fabrics with other nonwoven or woven fabrics, offers new capabilities in product development. This work is aimed at exploring the use of site-specific hyrdoentangling (i.e. hydrostitching) to combine dissimilar fabrics and examine the bonding characteristics of this process. Prior effort has shown the efficacy of this process, but has been limited in a materials analysis to prove the true capability.

This design project is supported by the Nonwoven Institute at the Wilson College of Textiles. The primary objective of the research effort is to 1) modify and existing lab-scale hydroentagling unit to a roll-to-roll process that allows for systematic control of hydrostitching, 2) characterize the entanglement properties between two fabric and the effect on overall bond strength, and 3) develop a lab-based module that will demonstrate the hydroentangling process.

Sponsor

Department of Physics (Bochinski & Clarke)

Department of Textile Engineering, Chemistry & Science (Gorga)

Team Members

Nathaniel Klimek, Jacob LaRoe, Jackson Parker

Project Description

Our project is the incorporation of nanoparticles into shape memory polymer. The goal is to have the photothermal actuation of our silver embedded SMP be comparable or better than the actuation of conventional heating.

Photothermal heating is an unusual process whereby metal nanoparticles convert weak light directly into thermal energy. Prior research has shown the ability to induce photothermal heating of polymers embedded with well-dispersed metal particles (e.g. Ag nanoparticles) to hundreds of degrees. This localized, laser-activated heating is of particular interest for annealing polymers and controlling the actuation of shape memory polymers (SMP). An observed challenge is the poor chemical compatibility between the target polymer and the nanomaterials. Opportunities exist in using a non-SMP polymer compatibilizer that enhances the dispersion.

This project will support a collaborative research effort between the Department of Physics (Bochinski & Clarke) and the Department of Textile Engineering, Chemistry & Science (Gorga). The primary objective of this project is to define the important design parameters/restrictions that would enable incorporation of any particle (with or without a compatibilizer) into an SMP while preserving shape memory behavior?

Sponsor

Nike, Inc.

Team Members

Joseph DiCesare, Edgardo Lopez, Jakie Revels

Project Description

Many textile processes can benefit from the use of innovative “Green” technologies, which results in the improved environmental sustainability of an existing product.  For example, Nike’s Green Chemistry Program is designed to drive innovations in product chemistry (which includes final product, materials, and processing), through the application of the Green Chemistry Principles and hazard & exposure data. The program allows us to inform and guide our suppliers and acts as a way for them to communicate their innovations/improvements for recognition.   Of particular interest is the use of green chemistry to improve the production of synthetic leather.   There are a number of opportunities to “green” synthetic leather, both in process and material, that will improve human health and/or environmental impacts.

This project is sponsored by the Nike, Inc.   The objective of this project is to landscape existing commercial opportunities for improving synthetic leather, both the materials and processes used to manufacture them, using Nike’s Green Chemistry Program as a lens to evaluate alternative processes and materials.  This senior design team will be tasked to 1) assess current state of synthetic leather production, 2) identify and catalog existing, commercial opportunities for improving the process/material using Nike’s Green Chemistry Program as a lens to assess alternatives, 3) rank and quantify improvements based on Nike’s RSL/SCG criteria for environmental and human health profile as well as product performance and quality that could inform a hierarchy enabling us to rank suppliers’ materials.

We are hoping to receive process information from several synthetic leather vendors.  Receiving data such as chemicals used, process parameters, and material yield will allow us to better evaluate the different ways synthetic leather is produced from vendor to vendor.  Each vendor will remain anonymous for our projects sake and will be labeled “Vendor A”, “Vendor B”, etc.  Obtaining this information will give us a baseline for our future research, and will allow us to evaluate current and potential vendors.

Sponsor

NC State’s NSF Nanosystems Engineering Research Center (NERC) for Advanced Self-Powered Systems of Integrated Sensors and Technologies (ASSIST)

Team Members

Brian Coffin, Shadasia Edgerton, Anna Hall

Project Description

Wearable, wireless sensors that track a person’s motion would be observed as a paradigm shift in moving rehabilitation research from laboratory settings to real-world/in-home settings. The benefit of this real-time, real-effect monitoring is observed as means of quicker and more beneficial rehabilitation of the patient. To enable this, a wearable electronic system needed to be developed and tested.

This project is in collaboration with the Electrical and Computer Engineering department and is sponsored by NC State’s NSF Nanosystems Engineering Research Center (NERC) for Advanced Self-Powered Systems of Integrated Sensors and Technologies (ASSIST).  In addition, the teams will work closely with the Rehabilitation Engineering Center to identify the project metrics.

The goal of the project is to create a system capable of tracking the walking motion of a rehabilitation patient, outside of the lab, for a time period of one to seven days. This system should track step displacement and width, as well as elevation change and motion at the center of mass. The system should be easy to attach and detach with one hand.

Sponsor

Hanesbrands Inc.

Team Members

Ruthie Isaac, Alex Shore, Zahra Tayebali, Janelle Wilson

Project Description

There is no current standard test method that can quantitatively or qualitatively judge reduction of microbes that cause odor on apparel. Current tests are geared to AATCC and ASTM standards which are focused on complete kill of bacteria. This leads to applying a larger amount of anti-bacterial to achieve high kill rates but possibly more chemistry and cost than required for odor control.

This design project is supported by the Hanesbrand Inc., and is a continuation of a project started last year. Last year’s team worked on one short product line with one experiment. This year’s team will take what they learned and really develop a more thorough plan for creating an odor testing method that results in a viable testing solution. To do this, the objectives of this team will be to 1) identify odor causing bacteria and the best environment for them to grow, 2) determine minimum amount of common anti-bacterials to control odor, 3) determine the appropriate amount of kill to eradicate odor and develop test methods to develop marketing claims, and 4) compare cost for amount required for full log kill to the amount required for odor control

The objective of this project is to research and discover antimicrobial treatments that will work successfully with 100% polyester and 100% cotton jerseys. The test and solution will focus on eliminating bacteria needed for satisfactory odor control with a reduction on capital investment. The antimicrobial treatment must be able to withstand twenty laundry washes, and the treatment itself can not be flammable nor can it contain any metals. As for the cost, the price for the antimicrobial treatment for 100% polyester and the 100% cotton will be 2 cents per pound. A milk test will be performed on the fabric to help identify the odor scent and give the group proper information to construct an experimental excel table for evaluation. The milk test results will be determined by a subjective pass/fail method. Passing samples will be sent to a third party, MicroStar Labs, for AATCC Testing and bacterial evaluation at both 10 and 20 washes.

Sponsor

Elephants for Africa Forever

US Army Research Office

Team Members

Kristi Barnes, Keegan Ray, Caryn Siggins

Project Description

In South Africa, Human-Elephant conflict is a very big problem leading to poaching and senseless killings of wildlife. A private game reserve adjacent to Adventures With Elephants is experiencing huge elephant problems, particularly with their elephant bulls who are destroying lodges, housing, and infrastructure on a weekly basis. The damage has become such a problem that the decision to destroy the elephant is a real one and a decision will be made soon. This problem is not unique across Africa.

The goal of this project is to create an e-collar which is able to alert, warn and then give the elephant a negative stimulus when it approaches infrastructure, vehicles, lodges, houses etc. This collar must also be able to feed-back vital information to the reserve managers and researchers so that they are able to monitor and record the elephant’s behavior in order to best manage the elephants. Resulting in curbing damaging and dangerous behavior by elephants to the game reserves and local communities infrastructure and its visitors / personnel.

This project is in collaboration with the Electrical and Computer Engineering (ECE) department and is sponsored in part by Elephants for Africa Forever and the US Army Research Office. A collar is sought that is 1) ‘elephant proof’ and 2) be equipped with GPS for tracking, a mobile radio system for data communications and remote control, a wireless beacon recognition system (e.g., WLAN or other), a wireless control system (that may be configured wirelessly), an alert system (vibration, audio), a shock correction system (like wireless fence for dogs), a power generation system (such as solar), and a control system for operating these modules. The TE/TT team will be charged with creating a solar energy harvesting collar that is elephant proof and interfaces with the design requirements of the electronic system that the ECE team will be developing.

Sponsor

American Flocking Association

Team Members

Keyah Barksdale, Antonia Caldwell, Stewart Coates II

Project Description

The overarching objective of this project is to develop a new, high volume, profitable and innovative application for flocked materials, specifically aimed toward improved medical bandages.  New bandages such as HemCon, have the ability to clot blood rapidly while allowing for breathability and antibacterial properties. Using flock as a replacement for gauze on a bandage is beneficial due to flocked materials high surface area. Having the flocked fibers be able to be arranged linearly enables more fibers to be placed onto the surface. The more fibers that can be arranged on a surface, the higher the absorption of the material.

This project is sponsored by the American Flocking Association.  AFA seeks new applications to increase the product range of flocking.  The goal of the senior design team is to create a product that is innovative, affordable, and something that can be used in everyday life.  A high throughout process for flocking of medical bandages is sought, as well as a design of experiments for the evaluation of the clotting behavior of these materials.

Sponsor

Sector 212

Team Members

Lauren Cox, Joseph Hage, Josh Knippel

Project Description

Reusing and recycling post-consumer textiles to minimize global waste in an innovative, efficient and profitable way. Currently but not limited to, these textiles are converted into clean insulation materials for the automotive industry, carpet underlay for commercial and residential properties, insulation for homes and businesses and yarn spinning.

This project is sponsored by Sector 212, an industry consortium for recycled textiles.  The project should accomplish a complete market analysis with emphasis on industry’s trends, key players, product development and government regulations. In addition, defining product viability based on a comparison approach and cost analysis.

Sponsor

Johnson Controls Inc.

Team Members

Fernando Ascencio, Cheryl Coley, Jesse Edwards

Project Description

“To develop a fabric that is comfortable and holds up to everyday use of a car interior that is capable of harvesting and storing solar energy to be distributed for use to power systems in the vehicle.” – Group 9

Solar energy is observed as a means of reducing energy cost and improve energy efficiency of existing technologies. Johnson Controls Inc. has solicited a request to asses current innovations in solar energy harvesting based on textile materials. The goal of this research is to develop a textile-based prototype that can harvest solar energy, store the energy, and deploy the energy on-demand in automotive seating technology.

The objective of this project is to survey existing materials which can be used as solar textiles and also developing new materials which can be used in automotive seating and can harvest the solar energy and store it. This will include a thorough research of current technologies and existing materials and the development of a prototype that can capture the solar energy and store the energy.

Sponsor

Hanesbrands Inc.

Team Members

Meredith Mckague, Shikha Singh, Jordan Sorensen

Project Description

Hanesbrands has been revolutionary when it comes to tags especially with their tagless t-shirts.
Marketing would like to help the consumer determine when they should replace their garments
based on a number of washings similar to the way razors have a strip that fades over time letting
the consumer know when it is time to replace the razor.

This design project is supported by the Hanesbrand Inc. The primary goal is to develop a new revolution in tags on t-shirts: one that will fade over time due to the number of washes. The design group will need to create survey of similar technologies in other products to define the state of the art of the proposed technology and determine the best course for the born on date tag. In addition, the team will need identify and evaluate different ink-binder combinations that produce different levels of fading with wash cycles.

Sponsor

Hunter Safety Systems

Team Members

Dillon Dunn, Matthew Kent, Carl Ivarsson, Jenn Lee

Project Description

Current hunter safety products are often bulky and uncomfortable for the user, typically resulting in non-use. New designs for improving the wear-ability are sought with key metrics of a reduction in total system weight, as well as an increase in total system comfort.

This project is sponsored by the Hunter Safety Systems, a leading provider of safety-related hunting products in the world. To maintain that stronghold on the market, we MUST continue to innovate. Customers expect new technology every year that will enhance their hunting experience. The team’s  objective is to create the lightest, most comfortable and easiest to use safety equipment that has ever been manufactured.This project will seek to explore textile-based HSS products and develop a prototype solution for improved product solution.

Sponsor

US Army Research Office

Team Members

Macon Adams, Shannyn Holder, Hilary Walker

Project Description

Military Working Dogs serve in a wide range of capacities within the US military including security, patrol, explosive detection, tracking, search and rescue, guard, sentry and tactical duty.  During advanced training multi-purpose canines will receive negative reinforcement during a “mis-bite” on a handler or trainer.  This negative behavioral reinforcement can remain throughout training and into tactical situations where a canine will disengage from a bite for fear of punishment from its handler.  Disengagement during a tactical operation poses a significant liability, not only to the canine but the team the canine supports. Thus, this project, sponsored by the US Army Research Office and in collaboration with the Materials Science and Engineering Department seeks to design and create a prototype bite sleeve that mimics human skin but at the same time protects the handler and the canine. A test bite suit will be developed and tested that mimics the tactile sensation, puncture resistance, smell, and taste of skin for military working dog-combat canine bite training.

Project Goals and Objectives

1. Determine:  The material characteristics and properties that can be utilized in a canine bite sleeve to mimic human bone, flesh and skin.
2. Determine:  The most suitable design of the bite sleeve as well as methods of improved functionality and the safety of the dog as well as the handler.
3. Create:  An improved, lightweight, form fitting canine bite sleeve that mimics the shear strength, puncture resistance, plasticity, and tensile strength of human skin while optimally protecting the canine’s health and the safeguarding the handler from skin punctures, tears and severe bruising.

Sponsor

Nike, Inc.

Wilson College of Textiles

Team Members

Forrest Cannon, Hannah Dedmon, Carl Escriva, Jeremy Lewis

Project Description

As product developers innovate in performance textiles, one issue for commercialization is speed-to-market.  During the commercialization, technologists need fast and accurate methodologies to assess product viability.  Moisture wicking apparel is a product line that continually demands new innovation.  Brand owners are demanding that materials be made from sustainable processes and material. The goal of this project is to examine replacements of the traditional fluorocarbon coatings for water repellency and to evaluate moisture vapor transmission rate (MVTR). The team will be responsible for developing a method for continuous monitoring of MVTR for multiple samples in C&C humidity chamber located within the senior design laboratory.

This project is sponsored by the Nike Inc. and the Wilson College of Textiles.  The project has three primary objectives:

1. Develop a technique for high throughput Moisture Vapor Transmission Rate (MVTR) testing utilizing the C&C humidity chamber as a function of temperature and humidity
2. Perform a competitive analysis of high moisture wicking garments on the market today
3. Work with the sponsor to assess the practicality of MVTR test methodology by evaluating new coatings on a benchmark textile.

Sponsor

Hanesbrands Inc.

Team Members

Kelly Fredenburg, Maria Menjivar, Trevor Summers

Project Description

One of the major complaints in women’s bras is underwire failure.  The sponsor, who is a leader in the commercial sales of women’s bras receive their metal underwires from two different suppliers.   Reasons for failures are sought, as well as a plan to improve the current designs and materials.   In particular, non-metal support approaches are sought by the industry that could potentially replace the metal under-wire.

This design project is sponsored by Hanesbrands Inc. and will be in collaboration with the Materials Science and Engineering department.  The purpose of this project is to analyze current underwire metal and determine why failures maybe occurring and develop a recommendation to improve the current design and material.  The next phase will be to design/develop a non-metal support solution to replace the metal underwire.   The TT/TE team will be tasked 1) to develop and design a non-metal support that could replace the metal underwire and, 2) work with MSE team for design and construction of prototype developing solutions as well as analysis.

Sponsor

Dr. Orlando Rojas (Department of Forest Biomaterials)

Dr. Julie Willoughby

Team Members

Scott Schreiner, Matthew Shurer, Meghan Wilt

Project Description

The utilization of renewable resources is becoming increasingly important as the supply of petroleum-based materials continues to dwindle. The abundance of lignin, the second major component of wood and annual plants, provides an ample feedstock for conversion to viable macromolecule products. A simple reaction to functionalize lignin by replacing –hydroxy and –methoxy groups with –ene components has been developed. The –ene components provide lignin with reactive groups for subsequent modification. Applying a coating of functionalized lignin to filament fiber or yarn will allow for the creation of products with tunable surface chemistry.

Dr. Orlando Rojas, a professor in the Department of Forest Biomaterials, will be the sponsor for the project along with assistance from Dr. Julie Willoughby. The goal of this project is to investigate alternate processes that have the potential to produce modified lignin on an industrial scale.