2020-2021 Senior Design Projects

Sponsor

Velcro USA,Inc

Team Members

Sara Abushakra, Molly Campbell,  Reed Cannon, Jackson Young

Project Description

This project’s goal is to produce a conductive hook and loop using innovative technology and prove its effectiveness in a final product, such as a smart knee brace. Velcro USA Inc. is motivated to expand its portfolio by offering products beyond just fastening devices. Therefore, the design team has developed the idea of using a conductive hook and loop to bridge the gap between their current products and the world of smart products. 

The design team began this process by first benchmarking conductive hooks and loops that were already on the market, looking for key measurables such as peel and shear strength, end to end resistance, sheet resistance, and through resistance to compare their eventual prototype to. The next step for the team was to decide how they wanted to pursue creating their own conductive hook and loop. After primarily researching conductive inks, paints, and pastes, the team ultimately decided that conductive inks were the best choice due to their higher conductivity than the other two options. The team also needed to decide on what wearable application they were interested in pursuing, and began ideating on applications such as smart masks, smart masks, smart sportswear, and smart knee braces. With guidance from their sponsor, Velcro USA Inc., the team ultimately decided to pursue the creation of a smart knee braces with the integration of a conductive hook and loop. From the team’s research on conductive inks, they wanted to try to coat hook and loop samples with two inks: Liquid-X and Oreltech, because they are nanoparticle free, had good conductivity, and good adhesion to different materials. The team started with the Liquid-X ink, which involved first pretreating their polypropylene hook substrate with UVO, then both spray coating and dip coating the substrate, and then curing the substrate in the oven. The first prototypes made by this process did not come up with good results- having high resistance and very low uniformity in the coating. The team then decided to change their pretreatment method to plasma cleaning instead of UVO, and try both the Liquid-X and Oreltech inks. The plasma cleaning proved to be much more effective, providing a much more uniform coating and low resistance with the Liquid-X ink. The Oreltech ink was not as effective because the team did not have the proper equipment to effectively cure the ink. Right now the team is still making prototypes, primarily using a plasma pretreatment and using the Liquid-X ink.

Sponsor

The North Face

Team Members

Emily Benz, Erin Magee, Grace Davis, Maggie Riley

Project Description

For this project, The North Face has tasked this team to design a fabric incorporating hemp fiber that can replace the fabric that is currently used in their Jester backpack. The motivation behind creating this new fabric has to do with creating a better environmental impact for the brand and their products. Although The North Face currently uses recycled polyester, which makes it more sustainable than non-recycled polyester, it is a synthetic fiber which is non-biodegradable. Hemp is a natural fiber which means that it is biodegradable and easily breaks down and disintegrates into the environment. The challenge associated with this project is having the new fabric meet all the same physical specifications as the current fabric, but incorporate a natural fiber. Research and benchmarking for the team involved testing the mechanical properties of hemp-incorporating fabrics currently on the market against the original TNF fabric. From there the team began applying their findings to create our prototypes. Our team created two intimately blended yarns both using hemp, one that is a hemp-cotton blend and one that is a hemp-polyester blend. These two yarns will then be used to create three different woven fabric constructions; a plain weave, a twill weave, and a ripstop weave. Each fabric will have a DWR finish with a polyurethane coating applied to the back of the fabric. The fabric prototypes will be evaluated on its strength and meeting The North Face specifications, the most promising prototype will be made into a sample backpack.

Sponsor

Under Armour

Team Members

Emilie Phan, Devlin Santos, Susie Xu

Project Description

The Fourth Industrial Revolution (Industry 4.0) is the automation of traditional manufacturing and industrial practices that focuses on interconnectivity, machine learning, and real-time data updating. As part of the Fourth Industrial Revolution, it is expected automation and simulation programs will increasingly come to meet the process improvement demands of both manufacturers and product designers. As originally proposed by Under Armour, our project focused on trying to improve the production process of Under Armour using simulation software to simulate the properties of textile garments. At the beginning of the project planning and research were focused on identifying various programs and systems which could potentially meet Under Armour’s needs and offer the most additional value to its designers. The first program that received our full attention and evaluation was WiseTex, a composite yarn physical property simulation program. Most promising about this program was its capability to account for changes in the fiber composition of unique yarns. However because this program was more focused on composites and numerical outputs, it could not meet the needs of Under Armour’s designers. It was concluded that current on market programs were not able to surpass the programs Under Armour was currently using for soft textiles. After this, our attention was focused on finding ways to improve on one of Under Armour’s current used programs: CLO3D, a unique garment simulation program that focused on modeling the way a fabric conforms to body structures. We decided to focus on data collection as the area for most improvement in the program with the assumption that better data outputs more realistic simulations. By comparing test apparatuses widely accepted to our improvements with 3D technology, we hope to provide more detailed and accurate readings of a qualitative property. As this project moves towards its conclusion, we expect to deliver to Under Armour a unique model which could more accurately predict the physical properties of fabrics simulated in CLO, thereby improving the utility of the product as a whole, greater insight into how individuals understand and perceive the drape of a product, and a unique method for measuring the drape of fabric using 3D scanning technology.

Sponsor

Stryker

Team Members

Noel Buitrago, Sam Groce, Chase Hunsaker, Kasem Qassem

Project Description

The pervasiveness of pressure ulcers and other hospital-acquired pressure injuries has become a grave challenge within the hospital setting. Commonly found in patients of advanced age or limited mobility, these injuries can have serious health repercussions and require expensive treatment. However, these afflictions are entirely preventable and companies like Stryer work to combat them by developing advanced surface cover technologies. Currently, this technology is reliant upon polyurethanes, which possess great chemical resistance yet lack the breathability necessary to prevent pressure wounds. It is the goal of this project to design an improved surface cover in order to mitigate, if not eliminate, the possibility of pressure wounds within the hospital setting. 

We have worked vigorously to research, test and implement innovative materials in order to further the potential of bed covers in a medical setting for both the patient’s comfort and the wellbeing. Initially, we worked as a team to establish key measurables that would need to be met by the end of the project, which included: breathability, chemical resistance, fluid resistance, and mechanical abrasion resistance. Identifying measurables allowed us to research materials that satisfy the end goals of the project, including rain jacket technology for its fluid resistant and breathable properties. From this research, we utilized standardized test methods to assess these materials for our key measurables. Gathering results for materials provided technical justification for the construction of our first prototypes, which was a series of multilayered structures. We employed the same standardized test methods to evaluate our prototypes against our benchmark data. Prototype evaluation led to a second round material selection, during which we were able to identify a bonding method and coating method for our second round of prototypes, which are still undergoing testing. 

Even with a month remaining in the semester, we have learned many lessons. One significant takeaway from this experience has been the importance of asking questions. There were instances during all stages of the project where asking more questions, specifically regarding resources within the Wilson College of Textiles, would have made the process easier. Secondly, the importance of setting due dates for tasks has been noted over the course of the project as set dates assist in keeping long term projects on track. Lastly, we learned to expect the unexpected as delays and unforeseen issues tend to arise. Preparing contingency plans in anticipation of setback or failure can minimize their impact on the project.

Sponsor

Carpe

Team Members

Amy Cottongim, Courtney Michaels, Nidhi Godthi

Project Description

Millions of Americans suffer from hyperhidrosis and there are currently no textile products that have been developed to solve it. The problem that people with hyperhidrosis face is that their hands sweat at higher rates, thus their hands constantly feel sweaty and uncomfortable. Carpe, an antiperspirant lotion company, collaborated with the senior design team to alleviate this unpleasant health condition by creating an On-The-Go Sweat Towel.

The On-The-Go Sweat Towel was envisioned to be a compact, lightweight and portable towel to be carried around in the customer’s pocket, ultimately allowing the customer to thrive despite their overproducing sweat glands. The design team seeks to create a product that addresses the following measurables: moisture pick-up, absorption, drying rate, launderability and abrasion resistance.

The team began the design process with extensive research and benchmarking analysis of moisture management fabrics and competing products. This began the ideation and concept selection process. Ideas were organized based on the measurables they addressed. Several prototypes were created and evaluated during the spring semester, until a final design was selected. This design met the critical values of the measurables and accomplished Carpe’s main priority of removing sweat from the skin’s surface. Although the design process involved many failures along with successes, the team was proud to present their final product at the end of the year.

Sponsor

U.S. Army Pine Bluff Arsenal

Team Members

Alyson Barnes, Jakub Sciora, Valerie VanDerveer

Project Description

The U.S. Army Pine Bluff Arsenal (PBA), based in Arkansas, has a small textile facility that makes patient protective wraps (PPWs), IFS socks, and masks. The main focus of our project was to increase throughput of PPWs, which are fabric bags used to transport the bodies of injured soldiers during combat, since manufacturing them is a complicated process and PBA currently makes 12-15 units per week. Along with increasing throughput, we were tasked with automating the inventory system to decrease the time it takes to complete and to improve the ergonomics of their manufacturing and inspection process.

Simio simulation software was used to model Pine Bluff’s current facility layout since we were unable to travel to the site. The manufacturing facility was modeled based on numbers collected during a previous time study conducted by PBA and the resulting simulation made 11 PPWs. After the first simulation, new layouts were simulated to determine if moving machines or making a U-shaped layout would increase throughput by decreasing the time required to travel between machines. After receipt of the original documentation on PBA’s PPW layout, some changes were made internally by PBA including rearranging, removing, and adding machines. At this point, the focus of the project shifted towards accurately simulating this new layout in order to evaluate the impact of the changes on throughput compared to the previous layout and determine ways to further improve the layout. From simulation and survey feedback from current machine operators, it was determined that the final iteration of the updated process should be focused around adding inspections throughout the process to maintain product quality, but lessen the time required for end product inspection and repairs.

 PBA currently makes complete inventory counts by hand once every two weeks for all supplies. A new system was created using a wireless barcode scanner to identify raw material and a backend tracking software using Microsoft Excel Visual Basic Application (VBA) coding. The final result combines the portability of a hand scanner with a digital user interface to reliably monitor the supply of raw material located in their inventory. Users can update multiple materials simultaneously, utilize error-proofing methods, and save time in the inventory count.

 A major takeaway from this project was understanding the importance of clear communication with the team and sponsor to interpret the manufacturing process without seeing it in person.

Sponsor

Hansae

Team Members

Faith Hanford, Nils Menz

Project Description

The goal for this project was to model a manufacturing process of disposable isolation gowns that would be economically viable in the United States.  To start, we began researching what the current manufacturing process looked like and what steps were required in order to produce the finished product.  From our research, it was clear that the amount of manual labor required in the traditional process was not feasible to duplicate in the United States.  With that knowledge, we went into a period of ideation where we brainstormed alternative methods to reduce the need for manual labor by increasing automation in the process.  We began looking into current existing technologies that could be used to replace some of the traditional mechanisms, such as automated spreading and cutting systems. We developed a list of various machines that could be used in the process. We investigated the different price points and production capabilities to determine which machines would best meet our output requirements.

Looking even further into details of the process, we learned that the sewing step specifically required the most time and manual labor.  With that information, our team began another round of ideation focusing solely on potential sewing alternatives. From our ideation followed by research, we learned about the possibilities of ultrasonic welding. 

Ultrasonic welding was an exciting and promising alternative to sewing.  In order to utilize the benefits of welding in the gown manufacturing process the design and construction of the gown needed to change.  At this point the team conducted a third ideation round focusing specifically on the gown design and method of construction. From this phase, two different types of gown designs were identified and developed into prototypes, a design with two separate components and a design with a singular component.  These prototypes were compared by closely analyzing their performance in the construction step of the process. We learned from our analysis that the two piece design actually resulted in more adhesion steps than the traditional sewing, even with the use of the welding machine.  Looking at the one piece cut design, we were able to create a method to construct the gown that minimized the adhesion steps and simplified the process overall, by utilizing a specialized method of welding. It is the main concept of this prototype that our group intends to use to finalize the project.

Sponsor

ASSIST

Team Members

Coby Hart, Katrina Bach, Hannah Russell

Project Description

Our team, Flexible Heat Sinks for Clothing Integration, was tasked with designing and prototyping a flexible heat sink (HS) for use with a flexible thermoelectric generator (TEG) designed by our sponsor, ASSIST, an NSF-funded engineering research center focusing on the development of self-powered, wearable, for health and environmental monitoring. Additionally, we were tasked with determining appropriate methods of integrating the TEG and HS into a wearable garment. 

A TEG is a device that uses the Seebeck effect to convert heat flux into electrical energy. Flexible TEGs are being developed to harvest thermal energy from the human body to be able to power medical or other low power wearable devices. Heat sinks are important for maintaining the temperature difference between the two sides of the TEG which keeps the TEG performing appropriately. 

Our primary goals are to design a flexible heatsink that could achieve 15% of the flexibility of our sponsor’s TEG device, and improve the performance of the TEG by at least 30%. Through research our team identified several potential materials that could be used to fabricate such a product and eventually decided on using a 3D printable thermoplastic polyurethane called Ice9, produced by TCPoly of Atlanta, GA. We were attracted to the 3D printable nature of the material and its potential for rapid prototyping. Unfortunately, we eventually had to resort to having TCPoly print our designs due to difficulties printing the material ourselves. 

To evaluate our heat sinks we put together and experimented with our own test methods and setups. The first thing we tested was the effect on the open circuit voltage of the TEG when our heat sinks were attached. We did this using several different setups from hotplates to heat pipes. The bench-top setup results have been promising, showing a clear ability of our heat sinks to make the system more responsive to temperature fluctuations and generate a higher TEG open circuit voltage. Eventually we plan to test the TEG and HS system on a human subject. 

In alignment with our two main project goals we developed and performed a simple bend test to evaluate the flexibility of our designs. Using Image J software we captured and analyzed photos of the HS bending with varying weights applied. We then analyzed and concluded that several of our designs were able to achieve the 15% flexibility goal at an acceptable amount of applied weight. 

When working with newer technology, and a research heavy project, one needs to realize that there will always be changes. Developing a new product requires a dynamic mindset and ability to ‘be flexible’ around goals, testing set ups, resource allocation, and overall information available on the subject. Team 11 learned how to roll with the punches with this project, something the whole gang is thankful for.

Sponsor

Hanesbrands, Inc

Team Members

Shelby Dew, Grace Ngonyo, Teagan Lowman

Project Description

The focus of this Hanesbrands, Inc sponsored Senior Capstone Design project is to promote the wellbeing of Gen-Z and the impact this generation has on sustainability, while also connecting the impact that COVID-19 has had on this generation living, working and learning from home. Design Team 4 has been tasked with identifying specific products and functions that align both the Gen-Z customer needs with combining attributes of wellness and sustainability to create a new product, process, and brand concept for the Hanesbrands, Inc organization. We agreed upon three major fabric goals for the new product which are to promote comfort, be sustainable in process and materials, and promote the wellbeing of the Gen-Z consumers. The final product is a multi-purpose towel made from sustainable polyester microfiber material, with its goal being to replace everyday single-use cleaning and care products around the house. A total of four benchmark products were tested and evaluated in the first stages of this project. From the testing results, the Durafresh benchmark product was then chosen as a reference for the first iteration of prototypes, which included five various materials. The five first-iteration prototypes were then tested, and their performance was compared to the chosen benchmark product. From this evaluation, a final iteration prototype and its materials were chosen to be a recycled polyester microfiber towel with the fabric goal of replacing everyday single use products around the house in a sustainable fashion. This towel will be marketed under the proposed new Hanesbrands, Inc line Hanes for Home.

Sponsor

Hanesbrands

Team Members

Vince Varju, Cristina Guillen Diaz, Kitty McKay

Project Description

Our team was tasked with developing consumer facing packaging for Hanesbrand Inc. for use in retail stores that would tell a sustainability story. The focus of our project was the replacement of low-density polyethylene (LDPE) clear bags and paperboard holders currently used by Hanesbrand Inc. with a sustainable alternative. The expectations of the project and the project scope were very broad from the beginning, and we worked hard to ideate on potential solutions. Our final tally of concepts reached over 60 ideas! These ideas had to be narrowed down extensively through a concept selection process where wilder proposals, such as edible packaging, were analyzed critically through a Pugh Matrix and ranked. From our top-ranking ideas we selected several key concepts, namely the PLA bag clip, PLA compostable bag, and knitted hemp mesh bag which met the necessary criteria. After further technical evaluation, the mesh bag was shelved and the PLA bag and clip moved on to the next phase of prototyping.

The PLA bag and clip had to be initially prototyped externally. The PLA bag sample and roll were ordered from China and the PLA clips were printed by the D.H. Hill Library MakerSpace Staff and Senior Design personnel. The clip designs were originally discovered on Thinginverse.com, an open source page for 3D prints. We printed about 11 different designs and picked the 3 with the most secure closings, since that was a high priority. The clip with the most reusability potential was redesigned on Solidworks in order to alter the dimensions and add a hook for retail display versaitility. Once we received the PLA roll, we used the Sonobond in the senior design lab to bind the panels together. We then combined the clip, our label design with sustainability marketing, the PLA bag, and Hanes product to create our final packaging look. Our final phase was testing the strength of the hook with a modified tensile test, and performing a weight test using increasing loads inside the PLA bag to evaluate slippage between the bag and clip.

Sponsor

Hanesbrands, Inc

Team Members

Yonael Berhe, Carter Davenport, Aaron Dreyer, Brennen Smith

Project Description

The main objective of this project was to create a new product tailored to fit within Champion Brand’s gamer line of products, tailored towards Gen-Z. The product that was chosen to be created was a backpack. What is intended to be accomplished through the development of this bag is a more cost effective, lightweight, minimal bag as opposed to current bags on the market that are created specifically for gamers.

The near whole garment knit construction and high level of customization of the bag is what will make it a unique and viable addition to the current market. Almost every aspect of the bag can be produced using a flat bed knitting machine, with the end goal of creating a knitted bag with minimal cut and sew. This flatbed knitting process will eliminate manufacturing steps, in turn reducing production costs. Flatbed knitting also provides a high level of customization, allowing for extremely versatile pocket shapes and aesthetically pleasing patterns all to be constructed in one manufacturing step.

The various types of fabric construction, fiber types, and fabric finishes were the main focuses of the team throughout the semester. Knit fabrics are naturally porous and possess high stretch. These typical attributes of knitted fabric had to be addressed for their use in a backpack, and were done so mainly through the development of a knit structure paired with specific yarns, a fabric finish, and knitting machine settings. Continuously developing these areas helped to optimize fabric cover, improve water repellency, and decrease extensibility. In the single process of knitting one of these bags to be sewn, there were also certain structures developed and knitted

that serve to provide padding in designated areas of the bag to provide impact protection for items being carried, as well as comfort to the wearer.

This year, the team learned much about what it takes to develop a product over an extended period of time. The main takeaway for the team was the fact that hardships and roadblocks will almost always play a part in the creation of a product, and that cannot stop you. It is important to keep a level head, trust in your teammates, and keep working towards your goals.

Sponsor

Bob Barker Company

Team Members

Celina Bailis, Leslie Belmonte, Kate Morgan, Lauren Poeschl

Project Description

Currently, the textile supplier Bob Barker supplies bed sheets, among other textile necessities, to correctional institutions. Customer feedback alerted Bob Barker to issues with the durability and longevity of their bed sheets. Inmates are able to destroy the sheets through tearing them into strips, unraveling them for thread, and staining them through extended use without washing. Some of the activities inmates engage in with the bed sheets have the potential to be life-threatening, so the Durable Linens Senior Design Team was keen to begin working on creating a safer and stronger bed sheet that would deter unauthorized, dangerous activity. 

Working with Bob Barker’s Product Development Team, Team 8 was able to settle on a variety of measurable characteristics that defined a durable linen while maintaining important aspects of current production. The goal of the project was to improve bed sheet performance in: tear strength, ball burst strength, abrasion resistance, stain resistance, and microbial resistance. Features to remain similar included cost, washability, comfort, and dyeability. The team brainstormed a variety of ideas, starting with inspiration from durable animal skin and shells, refining into manageable textile forms involving composites and high-performance applications before settling on a ripstop fabric construction with different variables to adjust. In order to establish benchmarking data and a baseline to guide the prototyping process, multiple ripstop fabrics, standard bed sheets, and current Bob Barker bed sheets were tested in the measurable areas. Once a sheet to beat was determined, a small design of experiment was devised to test how a ripstop fabric could be modified during prototyping. Weave patterns in the body and reinforcing yarns in the warp and weft directions could be changed to draw conclusions on what aspects of prototypes were affecting the mechanical performance of the fabric. 

Next, yarn was sourced from Bob Barker and McMichael Mills to use in ripstop prototype designs that had different materials and construction. After testing yarn properties, weaving of the ripstop prototypes began at the Wilson College of Textiles Weaving Lab. During production, the team began testing finishes and their effect on Bob Barker’s bed sheets to establish recommendations of treatments that could extend the sheets’ resistance to microbial activity and heavy soiling. With a plethora of data to interpret, the team could then justify a final design and finishes to Bob Barker that would result in a more durable linen with the capacity to give inmates a safer, while still comfortable, product.

Sponsor

Red Bull and Teijin Aramid

Team Members

Jordan Edmondson, Jamison Knickerbocker, Samantha Chalmers

Project Description

Wingsuits have remained relatively unchanged for the last decade and athletes are pushing themselves to new flight records, so the industry needs a wingsuit that can perform at higher levels. In partnership with Red Bull and Teijin Aramid, the Wingsuit Redesign team was tasked with optimizing the fabric choices, coating choices, and seam solutions for improved performance of wingsuits. Fabric materials and properties, including air permeability, roughness, strength, weight, durability, and safety were considered.

A 210D ripstop nylon with durable water repellent, UV resistant, and polyurethane coatings is the benchmark fabric currently used in wingsuits. Over time, the wingsuit’s performance decreases due to this fabric’s low durability and increasing air permeability through the fabric and seams.

While trying to improve durability and reduce permeability with a new fabric and coating, surface roughness was a critical property that still needed to be minimized for low drag forces on the wingsuit. Our team was determined to have a working wind tunnel to take drag force measurements on the fabrics, however, challenges with it led the team to explore other options in parallel. The team used TAC7 imaging for a subjective method of determining surface roughness along with slip angle tests for a numerical comparison. Coatings were applied to the three fabric constructions and underwent tensile, tear, and air permeability testing, as well as TAC7 imaging for surface roughness. Seam coatings and tape were applied to wingsuit seam samples and underwent tensile, air permeability, and thickness testing.

Each phase of testing allowed the team to make justifications on what fabric, coating, and seam solution would be the optimal combination, and a final prototype was created. The final prototype for an updated wingsuit material was a polyester/technora ripstop twill weave, with an updated coating, and with seam tape. The modifications to the fabric work together to create an impermeable, durable, and strong wingsuit material.

Sponsor

Gildan

Team Members

Alexander Depolt, Isaac Powell, Radhika Pal

Project Description

In recent years there has been a relative lack of innovation in cooling sock technology. Additionally, based on the customer reviews of many of the high-performance cooling socks currently available on the market, many do not exhibit a true cooling sensation. The goal for the Gildan Cooling Sock Commercialization project is to develop a high-end athletic cooling sock by optimizing performance and cost. Using last year’s senior design cooling sock team’s final prototype as our starting point, we first established a definition for cooling. Then, we moved on to conducting testing on the previous team’s prototype, specifically sweating manikin foot testing. By testing these socks against industry-leading benchmark samples, we came to the conclusion that we wanted to implement different technical yarn combinations in a three plaited structure for our first set of prototypes. Next, we outlined the testing procedures we could accomplish through TPACC and the senior design lab to collect data to show the improved performance of the modified cooling socks. One of the challenges associated with establishing a sound testing methodology was identifying an assortment of two-dimensional tests to analyze a three-dimensional garment. Through communication with class professors, TPACC, and Gildan, we selected MMT, Modified WATson, Qmax, and drying tests to assess various aspects that contribute to cooling. We then moved to prototyping using two new technical cooling yarns, and produced prototypes using the Lonati sock knitting machine at the ZTE Knitting Lab. Through this process we learned more about the manufacturing process and some considerations that should be made to improve manufacturing feasibility. Lastly, in our second round of prototypes we implemented a thinner sock design and reincorporated the channel design from the original pattern, which establishes a mind to function connection and enhances the aesthetic of the sock.