Sponsored by: Northrop Grumman
Project Summary
Northrop Grumman Corporation (NG) and the St. Thomas design team partnered together to design and build a polystyrene pre-expander for use at NG’s facility. The problem at hand pertains to the supply chain of polystyrene beads. During the traditional molding process, beads with a stock density are pre-expanded to a density of only 3%, increasing their volume, creating a lightweight material for molding products. NG requires their beads to be produced to a variety of densities at lower quantities. Since bead producers develop beads at a single density in high quantities, NG required a custom polystyrene pre-expander.
Design Goal
Develop a polystyrene pre-expander that alters the physical characteristics of the material through precise and controlled heat transfer processes. Utilizing the pre-expander will provide a more efficient and sustainable manufacturing process for NG’s facilities.
The deliverables for this machine include a functional automated pre-expander that meets the specific density requirements, a comprehensive user manual that includes operation and setup, servicing/trouble shooting guide, and a CAD model of the updated machine.
Design Constraints
- The developed machine shall take stock beads and pre-expand them to a desired density within the range.
- The GUI shall have control of the temperature with readouts between ambient and 200°C +/- 1°C.
- The machine shall fit within a 5-foot by 5-foot floor space with a maximum height of 7 feet.
- The GUI shall store historical data from previous runs including lot number, temperature, expansion time, and expansion date.
![From left to right: Raw vs. Expanded Beads](../../../../../_media-library/_images/ug-experience/senior-design/2023-2024/projects/t23-northrop-grumman-image1.jpg)
From left to right: Raw vs. Expanded Beads
Members of the Project Team
Student Team:
- Luke Corrigan - Major: Mechanical Engineering
- Logan Farner - Major: Computer Engineering
- Ben Goldman- Major: Mechanical Engineering
- Jack Hergott- Major: Mechanical Engineering
- Jacob Wilcox - Major: Mechanical Engineering
Industry Representatives: Noah Kopen, Noah Tews and John Feigum
Faculty Advisor: Jason Petaja
![Senior Design student team](../../../../../_media-library/_images/ug-experience/senior-design/2023-2024/student-teams/t23-northropgrumman-student-team-pic.jpg)
Pictured left to right: Ben Goldman, Logan Farner, Luke Corrigan, Jack Hergott, Jacob Wilcox