Every year, seniors majoring in textile engineering<\/a> (TE) or textile technology<\/a> (TT) at NC State University team up with a few classmates, as well as industry partners, to address a real-world problem for their capstone course. <\/p>\n\n\n\n Over the course of two semesters, they gain hands-on experience in the research and development (R&D) process for process and\/or product development. <\/p>\n\n\n\n \u201cI think Senior Design has been so helpful, because we got to learn how to start with research and then go all the way through prototype development,\u201d TT alumna Connie Wong \u201923 says. <\/p>\n\n\n\n Students are grouped into teams and assigned to projects based on their interests and leadership styles, helping to prepare these seniors specifically for the jobs they want post-graduation.<\/p>\n\n\n\n \u201cI’m currently looking to work with hands-on testing after graduation. I feel like this project specifically has helped us focus a lot on that. And we’ve learned a lot about what testing requirements look like and we even had to learn how to modify existing tests,\u201d TE alumna Lara Prosser \u201923 says. She and her teammates worked to find a biodegradable fiber for use in U.S. Army uniforms. \u201cI just feel like the more that I get to actually do hands-on testing, the more I realize just how fun it is.\u201d<\/p>\n\n\n\n The job outcomes for this new class of alumni \u2014 from Nike to Lenovo to research labs \u2014 are a testament to the strength of the Senior Design program. <\/p>\n\n\n\n Below, read more about the range of projects these Senior Design groups worked on and hear about the impacts of those projects in their own words. Click one of the links below to filter Senior Design projects by topic.<\/p>\n\n\n\n Nylon still makes up a large portion of textile manufacturing in the Department of Defense. However, nylon has significant environmental impacts over its lifecycle. This starts with a toxic production process and ends with a material that is slow to degrade with a legacy of micro-polymer pollutants when it does.<\/p>\n\n\n\n Our team was tasked with finding a biodegradable polymer that would have similar degradation properties to natural fibers and the mechanical properties of nylon. We gathered information on the market, obtained and tested samples and compared the samples against nylon benchmarks. <\/p>\n\n\n\n Our team proposed three polymer alternatives to nylon which have comparable mechanical properties and significant advancements in biodegradation. To do this, we utilized the Wilson College Spinning Lab, Weaving Lab and the Physical Testing Lab as well as the Senior Design Lab and the polymer and color chemistry facilities. <\/p>\n\n\n\n We started with testing the tensile strength, which is the maximum force a fabric can withstand before breaking, and biodegradation of the three polymers\u2019 yarn forms. We then wove the yarn into fabric and conducted testing methods such as abrasion resistance and breaking strength. These tests show that the three polymers are promising options. <\/p>\n\n\n\n Our challenge was to improve the moisture wicking ability (how certain fabrics stay dry by evaporating moisture off of the top layer of fabric) of the base layer of U.S. Army uniforms by 20% compared to the current Army standard. <\/p>\n\n\n\n We focused on increasing the wicking efficiency of the garment by 20% while also making sure to maintain comfort and remain Berry Compliant, which is the Army standard to keep manufacturing within the U.S.<\/p>\n\n\n\n From the beginning, we knew we wanted to incorporate wool as it has great wicking properties and could help keep the wearer warm. With the consideration of no-melt-no-drip or flame resistance requirements, we went back and forth with the amount of synthetic fiber used in the garment. The current base layer that is worn by soldiers is made of 100% polyester. <\/p>\n\n\n\n After a lot of trial and error and testing of different materials, we decided to use a combination 90\/10 wool\/nylon blend with extruded polyester. The garment will be a single jersey fabric. The interior of the channel will have a wool base and polyester channel, while the exterior side will be the opposite \u2014 polyester base and wool channels. These channels will allow for moisture and sweat to wick towards the sides and \u201cexit\u201d areas of the garment. <\/p>\n\n\n\n Getting to learn about the current uniforms worn by the soldiers in the U.S. Army! It was also interesting to learn more about the different properties of various fibers and materials.<\/p>\n\n\n\n The most valuable skill that we have learned from Senior Design is how to work effectively with a team. This class has pushed us to be professionals through the extended team project, leading meetings and using time management to conduct research, prototyping and testing over the semester. <\/p>\n\n\n\n Our challenge from Pine Bluff Arsenal, a U.S. Army installation in Arkansas, was to optimize the production of ghillie suits. These suits are the camouflage uniforms used in the military. We specifically focused on the head drape component which looks almost like a cape. <\/p>\n\n\n\n Our testing centered around how the process could improve to increase the efficiency of production and decrease labor costs. We utilized Simio, a simulation program that allowed us to replicate the floor plan of the Pine Bluff Arsenal facilities and run experiments to try and optimize the process. Dr. Joines<\/a> served as our main helper and guided us in the right direction. <\/p>\n\n\n\n Additionally, we ran sewing trials using a binding foot on a sewing machine, which is a tool that helps keep the sewing needle in place, to try and improve the speed of the machinery itself. We also drafted new manufacturing instructions for the suits at the plant. We were able to get a hold of examples online and around the university to serve as a guide. <\/p>\n\n\n\n We found that refreshing the current instructions will allow individuals with no prior experience to create the ghillie suits more efficiently. Additionally, we decided that purchasing another embroidery machine would be extremely beneficial for optimizing production.<\/p>\n\n\n\n Our favorite part of the project was getting the opportunity to learn and apply the Simio software. Without this project, we don\u2019t think we would have ever explored this software, but now we have unique knowledge on software that we can carry into the workplace. <\/p>\n\n\n\n We absolutely believe that we will be able to apply the skills learned in Senior Design to our upcoming jobs. While this project focused on a much smaller environment, it helped us gain experience so that we can apply that knowledge into larger projects in the future.<\/p>\n\n\n\n Stryker gave us the challenge of creating a patient elevator out of textiles. The goal was to come up with a way to lift a patient from the ground up to stretcher or bed with an emphasis on medical-grade, disposable textiles. <\/p>\n\n\n\n We created the Sliding Bar prototype which functions by sliding three thin, strong bars under the natural arches of a patient’s neck, back and knees. <\/p>\n\n\n\n There is a disposable nonwoven sheet that has three bars connected to either side. These bars are then pulled under the patient’s neck, back and knees, while the sheet follows. Once the nonwoven sheet has slid completely beneath the patient, the bars are then connected to a lifting system such as a crane. <\/p>\n\n\n\n It was interesting learning about the requirements and specifications for textiles used in a medical setting.<\/p>\n\n\n\n Our team spent a lot of time ideating throughout the year to come up with unique and groundbreaking ideas for our prototypes. We will use these ideating techniques to bring fresh ideas to our jobs.<\/p>\n\n\n\n Our sponsor, HanesBrands, challenged us to create a protective garment for school-aged children with a notification device that allows the wearer to send an alert to their parents or guardians. <\/p>\n\n\n\n We narrowed down our scope to focus on developing a fabric for hoodies and sweatshirts with increased levels of protection. We specifically evaluated cut-resistance and abrasion-resistance, or how much wear and tear the fabric could withstand without compromising comfort. <\/p>\n\n\n\n Our team created four different fabrics comprised of cotton, polyester and Dyneema that are all comfortable and have varying amounts of protection. Our four prototypes were core spun yarn interlock knit, plated jersey knit fabric, three-ply yarn interlock knit and a self-stitch interlock knit.<\/p>\n\n\n\n We conducted a variety of tests including an in-class hand comfort survey where we compared the softness of our fabric samples. We also tested the amount of pilling using equipment in the Senior Design Lab and a washer and dryer in the Zeis Textiles Extension<\/a> Dyeing and Finishing Lab.<\/p>\n\n\n\n There are constantly trade-offs when balancing protection with comfort, and it is not easy to come up with ideas to optimize these two properties. <\/p>\n\n\n\n We have learned valuable skills applicable to working in industry after graduation such as teamwork, communication, time management and presenting. Our team learned how to effectively conduct research during our ideation process. We also met with various professors and the NC State Police Department to gain a better understanding of our topic. <\/p>\n\n\n\n From our prototyping session, we learned what the product development process entails and observed how our prototypes were made from fibers into a yarn and then fabricated into a knit structure.<\/p>\n\n\n\n![\"Jocelyn](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100042\/IMG_6009-1024x576.jpg\")
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Military\/protective textiles<\/h2>\n\n\n\n
Team 9: Biodegradable Polymer Replacement <\/h3>\n\n\n\n
Sponsor: U.S. Army Combat Capabilities Development Command (DEVCOM)
Team members: <\/strong><\/h4>\n\n\n\n\n
![\"Three](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100045\/Team-9-edited.jpg\")
<\/figure>\n\n\n\nWhat was your challenge\/prompt from your sponsor?<\/h4>\n\n\n\n
What solution or end product did you come up with? <\/h4>\n\n\n\n
![\"A](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100115\/Team-9_Biodegradation-Images-edited.jpg\")
Team 10: HighSpeed Moisture Transfer<\/h3>\n\n\n\n
Sponsor: U.S. Army Combat Capabilities Development Command (DEVCOM)<\/h4>\n\n\n\n
Team members: <\/strong><\/h4>\n\n\n\n
\n
![\"A](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100045\/IMG_9887-edited-scaled.jpg\")
What was your challenge\/prompt from your sponsor?<\/h4>\n\n\n\n
What solution or end product did you come up with?<\/h4>\n\n\n\n
![\"A](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100046\/Team-10_working-edited.jpg\")
What was your favorite thing\/most interesting thing you learned about your subject area?<\/h4>\n\n\n\n
Where\/how do you think you\u2019ll apply the knowledge\/skills you have developed in Senior Design? <\/h4>\n\n\n\n
Team 9: Process Optimization of Ghillie Suits<\/h3>\n\n\n\n
Sponsor: U.S. Army Pine Bluff Arsenal<\/h4>\n\n\n\n
Team members: <\/strong><\/h4>\n\n\n\n
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![\"Three](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100046\/Team-13-edited-1.jpg\")
<\/figure>\n\n\n\nWhat was your challenge\/prompt from your sponsor?<\/h4>\n\n\n\n
What solution or end product did you come up with?<\/h4>\n\n\n\n
![\"A](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100047\/Team-13_working-2-edited.jpg\")
![\"Two](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100104\/Team-13_working.png\")
What was your favorite thing\/most interesting thing you learned about your subject area?<\/h4>\n\n\n\n
Where\/how do you think you\u2019ll apply the knowledge\/skills you have developed in Senior Design? <\/h4>\n\n\n\n
Medical\/safety textiles<\/h2>\n\n\n\n
Team 3: Textile Patient Elevator<\/h3>\n\n\n\n
Sponsor: Stryker<\/h4>\n\n\n\n
Team members: <\/strong><\/h4>\n\n\n\n
\n
![\"Three](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100047\/Team-3-edited.jpg\")
What was your challenge\/prompt from your sponsor? <\/h4>\n\n\n\n
What solution or end product did you come up with?<\/h4>\n\n\n\n
![\"Two](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100043\/Team-3_working-cropped-1024x1024.jpg\")
What was your favorite thing\/most interesting thing you learned about your subject area? <\/h4>\n\n\n\n
Where\/how do you think you\u2019ll apply the knowledge\/skills you have developed in Senior Design? <\/h4>\n\n\n\n
Team 5: Protect and Notify<\/h3>\n\n\n\n
Sponsor: HanesBrands<\/h4>\n\n\n\n
Team members: <\/strong><\/h4>\n\n\n\n
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![\"Two](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100123\/Team-5-1024x576.jpg\")
What was your challenge\/prompt from your sponsor?<\/h4>\n\n\n\n
What solution or end product did you come up with?<\/h4>\n\n\n\n
![\"A](\"https:\/\/tex-cloud-cdn.nyc3.digitaloceanspaces.com\/textiles-ncsu\/20231108100103\/Team-5_workingg-1024x768.jpg\")
What was your favorite thing\/most interesting thing you learned about your subject area?<\/h4>\n\n\n\n
Where\/how do you think you\u2019ll apply the knowledge\/skills you have developed in Senior Design? <\/h4>\n\n\n\n