Executive Summary

This annual report summarizes activities at Tech’s Advanced Engineering Design Lab (AEDL) for academic year 2020-21. The AEDL is a joint venture between the College of Engineering and the Kevin T. Crofton Department of Aerospace and Ocean Engineering and opened in the spring of 2020. The report includes sections on lab expenditures, student demographics, competition activities, and the AEDL COVID 19 response. This year 226 students completed all safety requirements but due to COVID 19 students were not permitted in the facility from March 16, 2020 until August 3, 2020. In August students were allowed to return to the lab in limited numbers. Some student competitions were canceled, others continued as virtual events and several other events were face-to-face. AED Lab equipment and material expenditures totaled $10,700, this year, with financial support for rent, equipment, and materials provided by Virginia Tech’s Aerospace and Ocean Engineering Department. In spite of unprecedented difficulties due to COVID 19, AEDL team members met the challenge of completing project goals and succeeding at sponsored events. Rocketry-at-VT earned 4th place out of 76 teams at the Space Port America Cup and Wind Turbine Team place 1st out of 13 in their Connection Creation event. Orbital Launch Vehicle Team had a very successful launch of their Test Turkey single stage, solid fuel rocket at the Kentland Farm launch facility. Test Turkey is a proof-of-concept design paving the way for the launch of the team’s two stage, high-altitude rocket Hokie 0.75 in 2022. In addition, this report summarizes information on AEDL’s participation in the STEAM Day 2020 and the College of Engineering open house, both virtual events. More details on lab operations are available from the Ware Lab/AEDL manager, Dewey Spangler ([email protected]).

Cover Design – Peter Means, Virginia Tech College of Engineering

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Table of Contents Executive Summary………………………………………………………………………………………… 2 Introduction………………………………………………………………………………………………….. 5 Student and Faculty Membership…………………………………………………………………………. 6 Team Competition Results and Annual Budgets………………………………………………………… 7 AEDL Team Innovations for 2020-21…………………………………………………………………….. 10 AEDL COVID 19 Response……………………………………………………………………………….. 11 New AEDL Equipment.…………………………………………………………………………………… 11 STEAM Day 2020 Virtual Event…………………………………………………………………………… 12 AEDL Demographics……………………………………………………………………………………….. 13 Team Lab Access…….…………………………………………………………………………………….. 18 AEDL Advanced Training………………………………………………………………………………….. 18 Lab Expenditures……………………………………………….…………………………………………. 20 Conclusion…………………………………………………………………………………………………… 21 Appendix A – Comprehensive List of AEDL Students for 2020-21………………….………………… 22 Appendix B – Rocketry-at-VT Competition Results for 2020-21…………………………….………… 27 Appendix C – ISE Senior Design Research on AEDL Optimization and Expansion………………… 29

List of Figures Figure 1 – Advanced Engineering Design Lab (AEDL) layout….……………………………………… 5 Figure 2 – Rocketry-at-VT team raises rocket Goddard onto launch pad.…………………………… 7 Figure 3 – Rocketry-at-VT ‘s successful launch taken from a GoPro 'pad cam'.……………………. 8 Figure 4 – Rocketry-at-VT’s launch from airborne drone perspective ………...... 8 Figure 5 – Orbital Launch Vehicle Team (OLVT) for 2020-21 with Test Turkey…………………….. 10 Figure 6 – OLVT Preparing Avionics and Successful Launch of OLVT’s Test Turkey…………….. 10 Figure 7 – Wazer waterjet router located in the AEDL and shapes produced with Wazer…………. 11 Figure 8 – Kevin Engle with OLVT and Hayley Capilitan with WTT STEAM Day Zoom Sessions… 12 Figure 9 – Daniel Melillo with Rocketry-at-VT and Bob Schoner with NASA SLI STEAM Day……. 13 Figure 10 – “How did you learn about AEDL?”………………………………………………………… 16 Figure 11 – Lab Square Footage based on total of 6,500 ft2…………………………………………. 17 Figure 12 – Team Access to AEDL……………………………………………………………………….. 18 Figure 13 – Rocketry-at-VT and OLVT at L1 Launch Sessions……………………………………….. 19

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List of Tables Table 1 – AEDL Faculty Advisors for 2020-21……………………………….………………………….. 6 Table 2 – AEDL Team Leads for 2020-21……………………………………………………………….. 6 Table 3 – AEDL Team Competition Results for 2020-21…………………..…………………………. 9 Table 4 – AEDL Team Contributions and Expenditures for 2020-21……………….……….……….. 9 Table 5 – Organization Speakers………………………………………………………………………… 12 Table 6 – AEDL Team Speakers for STEAM Day 2020………………………………………..……… 12 Table 7 – Gender and Ethnicity………………………………………………………………………….. 13 Table 8 – Academic Level………………………………………………………………………………….. 13 Table 9 – Academic Major………………..…………………………………………….……………….. 14 Table 10 – Academic Credit….……………………………………………………………………………. 15 Table 11 – Transfer-Student Population………………………………………………………………… 17 Table 12 – AEDL Team Members Receiving L1 Certifications………………………………………. 19 Table 13 – OLVT Team Members Receiving L1 Certifications………………………………………… 20 Table 14 – AEDL Expenditures for 2020-21…………………………………………………………….. 20

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Introduction

The Advanced Engineering Design Lab (aka AEDL) is an undergraduate design facility housed within Virginia Tech’s College of Engineering and Aerospace and Ocean Engineering departments at 501 Industrial Park Drive, in Blacksburg, Virginia. The facility is home to ten undergraduate teams from various departments within the college. AEDL management consists of: • Dr. Eric Paterson – Director • Dewey Spangler, PE - Manager • Bob Schoner - Assistant Manager

The AEDL facility spans over 6,500 square feet of space divided into the areas shown in Figure 1. Each area requires safety certification as specified in the AEDL Policy Manual. These areas include:

1. General Areas (Rooms 101 through 110, 115, 118) 2. Machine Shop – (Room 117) 3. CAD Lab – (Room 119) 4. Administrative Areas – (Rooms 111, 112 and 113)

Figure 1 – Advanced Engineering Design Lab (AEDL) layout.

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Student and Faculty Membership

226 students from various academic departments completed the AEDL general survey this year. Table 1 is a list of AEDL faculty advisors. Table 2 is this year’s team leadership. Appendix A has a comprehensive list of all student team members for 2020-21.

Table 1 – AEDL Faculty Advisors for 2020-21 AEDL Team Faculty Advisor Academic Department

3DPAC Craig Woolsey Aerospace and Ocean Engineering

inVents Rocktry Kevin Shinpaugh Aerospace and Ocean Engineering

Mars Madness Kevin Shinpaugh Aerospace and Ocean Engineering

MSAT Kevin Shinpaugh Aerospace and Ocean Engineering

NASA SLI Pat Artis Aerospace and Ocean Engineering

OLVT Kevin Shinpaugh Aerospace and Ocean Engineering

OLVT Pat Artis Aerospace and Ocean Engineering Kevin Shinpaugh Aerospace and Ocean Engineering Rocketry@VT

RockSat Kevin Shinpaugh Aerospace and Ocean Engineering

SEDs Rocketry Jonathan Black Aerospace and Ocean Engineering

Wind Turbine Team Matt Kuester Aerospace and Ocean Engineering

Wind Turbine Team Arthur Ball Electrical and Computer Engineering

Table 2 – AEDL Team Leads for 2020-21 AEDL Team Team Lead(s) Role 3D Printed Aircraft Team (3DPAC) Milad Rowshanbakhtfardian Co-Team Lead Dylan Adie Co-Team Lead Mars Madness Rudra Patel Co-Team Lead Charlyn Castillo Co-Team Lead Shuo Chen Co-Team Lead William Patton Co-Team Lead Mars Surface Analysis Team (MSAT) Shlok Agarwal Co-Team Lead Anthony Manchini Co-Team Lead NASA Student Launch Initiative (NASA SLI) Morgan Re Co-Team Lead Joseph Mensch Co-Team Lead Orbital Launch Vehicle Team (OLVT) Kevin Engel Co-president Adam Hinson Co-president Rocketry@VT Daniel Melillo Co-captain Trevor Bondi Co-captain RockSat-X Nicholas Jones Team Lead SEDs Rocketry Shreya Chandramouli Co-Team Lead Bryce Clegg Co-Team Lead Raeven Waters Co-Team Lead Elijah Gendron Co-Team Lead Wind Turbine Team Alvaro Armaza Co-Team Lead Hayley Capilitan Co-Team Lead

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Team Competition Results and Annual Budgets

Due to the continued COVID 19 concerns some sponsored competition events were canceled, others were held in a virtual format while some were face-to-face. Table 3 is a summary of competition results for 2020-21. The VT Wind Turbine team participated in an online version of their event and earned 1st place in Creation Connection. This event involves partnering with wind industry professionals to raise awareness of wind energy in local communities. Also, this involves teams working with local media to promote specific project accomplishments. More on this event can be found at:

https://www.energy.gov/eere/articles/california-state-university-maritime-academy-and-james- madison-university-claim-top

Rocketry at VT earned 4th place out of 76 teams overall at the Spaceport America Cup (see Appendix B for details). This appendix lists the universities and colleges that participated with Virginia Tech and indicates the highly competitive nature of these sponsored events. Figures 2 through 4 are from a Rocketry-at-VT test launch on May 1, 2021 at the Kentland Farm facility. The rocket, Goddard, named after rocket pioneer Robert H. Goddard, was 10’ – 6” in length, 8.25” in diameter and had a mass of 89 pounds. The airframe was carbon fiber with aluminum skeleton and bulk plates. The rocket used Aerotech N2220 'Dark Matter' propellant with a thrust of 650 pounds. The 4” diameter, 41” long motor burned 16 pounds of propellant in 5.4 seconds accelerating the rocket to an altitude of over 8,000 feet!

Figure 2 – Rocketry-at-VT team raises rocket Goddard onto launch pad during May, 2021 launch from Kentland Farms facility.

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Figure 3 – Rocketry-at-VT ‘s successful launch taken from a GoPro 'pad cam'. The 'Dark Matter' propellant produces thick black smoke with yellow sparks from the Titanium particles in the fuel grains.

Figure 4 – Rocketry-at-VT launch from airborne drone perspective (photo credit: Ethan Husman).

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Table 3 – AEDL Team Competition Results for 2020-21 Team Competition Location Ranking 3DPAC 3DPAC UTA Arlington Texas Canceled Nominated - NASA Human Exploration Rover Drivetrain and Mars Madness Huntsville, Alabama Challenge Technology Awards To be held RASC-AL Moon to Mars Ice and Hampton Roads Convention MSAT Sept. 23-25, Prospecting Challenge Center, Hampton, Virginia 2021 NASA SLI NASA Student Launch Initiative Huntsville, Alabama Canceled Non- Successful launch of Test Hokie, Kentland Farms, Blacksburg, OLVT competition proof-of-concept rocket Virginia Event 1st in COTS (10,000 ft commercial Rocketry at VT Spaceport America Cup (IREC) Virtual motor class), 4th out of 76 overall Non- RockSat RockSat-X Sounding Rocket Launch Wallops Island, Virginia competition Event 1st out of 13 - Connection Wind Turbine Team Collegiate Wind Competition Virtual Creation Event, 5th place overall.

Table 4 is a summary of all AEDL team budges for this year. AEDL teams reported over $189,000 in corporate, private, and university contributions for 2020-21. Expenditures totaled $42,600 for a net positive balance of $150,100.

Table 4 – AEDL Team Contributions and Expenditures for 2020-21 Virginia Team Corporate Private Total Expenditures Net Tech/DOE 3DPAC $0 $250 $750 $1,000 $3,100 $2,100 Mars Madness $0 $0 $2,500 $2,500 $296 $2,204 NASA SLI $0 $0 $500 $500 $774 $274 OLVT $14,000 $17,000 $4,990 $35,990 $9,100 $26,900 Rocketry at VT* $115,500 $0 $7,300 $122,800 $6,840 $116,000 RockSat $13,000 $0 $7,000 $20,000 $15,800 $420 SEDs Rocketry $0 $370 $870 $1,240 $2,400 $1,200 Wind Turbine $250 $0 $25,000** $5,250 $4,250 $1,000 Team Total $142,750 $17,620 $23,910 $189,280 $42,560 $150,098 *Corporate donation is for full access licenses to NX, StarCCM+ and is shared with OLV Team **$5,000 – Virginia Tech, $20,000 – US Department of Energy

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AEDL Team Innovations for 2020-21

AEDL teams innovate in the areas of solid rocket propulsion, wind turbine technology, aerial and space borne drones, and the use of advanced materials such as carbon fiber for rocket tube construction. This year was no exception with Orbital Launch Vehicle Team (OLVT) successfully launching their single stage rocket Test Turkey at Virginia Tech’s Kentland Farms launch facility, near campus. Currently, OLVT is working on development of Hokie 0.75, a two stage sounding rocket designed to place a 5 kg payload beyond the Karman Line (boundary between earth’s atmosphere and space). The team’s sub-scale version of this vehicle, dubbed Test Turkey, which was built to demonstrate the viability of key design elements in fight conditions. Test Turkey successfully few on a CTI L-1720 motor on November 7th, 2020, testing structural, electrical, and propulsion systems. The launch confirmed the team's ability to model and analyze data extracted from fight. OLVT plans to re-launch Test Turkey on a CTI N-10000 motor to better simulate the demanding fight conditions for Hokie 0.75 [1].

Figure 5 – Orbital Launch Vehicle Team (OLVT) for 2020-21 with Test Turkey (photo credit: Pat Artis).

Figure 6 – Left: Orbital Launch Vehicle Team (OLVT) preparing avionics hardware for launch from Kentland Farms facility. Right: Successful launch of OLVT’s Test Turkey single stage, solid motor rocket (photo credits: Pat Artis).

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AEDL COVID 19 Response

On March 16 of 2020, AEDL was closed to all students and faculty due to COVID 19. On August 3 teams were allowed to return to the lab under limitations mandated by the governor of Virginia. In order to accommodate students returning to campus a lab planning tool was placed in effect. The planning tool indicates the maximum number and placement of students in various project bays and common areas to conform with personal distancing rules. On June 1, 2021 mask requirements were lifted for persons who were fully vaccinated. Also, tour groups of 25 or less were permitted as long as everyone in the group was fully vaccinated. Project bay capacities were restricted to that which allows for safe personal distancing of six feet for unvaccinated persons.

New AEDL Equipment

This year, Ware Lab purchased a Wazer waterjet router (Figure 7). Due to limited space at the Ware Lab the router is housed at the AEDL and students from both labs will have access to the equipment on a first-come, first-serve basis. The 2’ x 2’ router is capable of cutting to high precession materials including plastics, carbon fiber, metal and glass. The router’s bed is replaceable once it is worn beyond use.

Figure 7 – Left: Wazer waterjet router located in the AEDL machine shop. Right: Aluminum, mirrored glass and carbon fiber shapes cut with Wazer.

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STEAM Day 2020 Virtual Event

On October 23rd, 2020 six AEDL teams partnered with the Ware Lab, The Society of Women Engineers, The National Society of Black Engineers, and The Society of Hispanic Engineers in the participation of 2020 STEAM Day (Science, Technology, Engineering, Arts, Math) virtual event. Table 5 is a list of organizational speakers and Table 6 is a list of AEDL team representatives who conducted Zoom sessions for the K-12 from many schools in the Roanoke service area. Figures 8 and 9 are screen shots of various online STEAM Day sessions. Using a similar format, AEDL and Ware Lab teams participated in this year’s College of Engineering open house event, providing virtual tours for students accepted into the college for 2021-22.

Table 5 – Organizational Speakers for STEAM Day 2020 Organization Speaker(s) Society of Women Engineers Lauren Chuderewicz, Marielle Buchy National Society of Black Engineers Quincy Brooks Society of Hispanic Engineers Louis Montane

Table 6 – AEDL Team Speakers for STEAM Day 2020 Team Speaker(s) RockSAT-X Nick Jones NASA SLI Bob Schoner Mars Madness Rudra Patel OLVT Kevin Engle, Adam Hinson Rocketry-at-VT Daniel Melillo Wind Turbine Team Kai Kato, Hayley Capilitan 3D PAC Milad Rowshanbakhtfardian, Dylan Adie

Figure 8 – Left: Kevin Engle with OLVT and Right: Hayley Capilitan with Wind Turbine Team during STEAM Day 2020 Zoom sessions.

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Figure 9 – Left: Daniel Melillo with Rocketry-at-VT and Right: Bob Schoner, faculty advisor, with NASA SLI during STEAM Day 2020 Zoom sessions.

AEDL Demographics

Ethnicity, gender, major, academic level, transfer information, and academic credit information is gathered each year when students complete the general admissions survey. Completion of this survey is one of several items necessary in order to receive a lab badge. Summaries of collected data are shown in Tables 7 through 10.

Table 7 – Gender and Ethnicity Gender Ethnicity Total Percent (total lab population) Female African American 1 0.4% Asian 7 3.1% Hispanic 1 0.4% Multi-ethnic 4 1.8% White 22 9.8% Male African American 6 2.7% Asian 35 15.6% Hispanic 14 6.2% Middle Eastern 1 0.4% Multi-ethnic 5 2.2% White 129 57.3%

Table 8 – Academic Level Academic Level AEDL Team Number Percent (total lab population) Freshman MSAT 4 7% OLVT 4 Rocketry-at-VT 6 RockSAT-X 1 Sophomore 3D PAC 4 31% Mars Madness 2 MSAT 4 NASA SLI 7

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OLVT 16 Rocketry-at-VT 21 RockSAT-X 5 SEDs Rocketry 4 Wind Turbine Team 6 Junior 3D PAC 3 35% Mars Madness 4 MSAT 18 NASA SLI 2 OLVT 34 Rocketry-at-VT 2 RockSAT-X 10 Wind Turbine Team 6 Senior 3D PAC 2 26% AOE Lunar Rover 4 Mars Madness 4 MSAT 6 NASA SLI 1 OLVT 12 Rocketry-at-VT 11 RockSAT-X 5 SEDs Rocketry 5 Wind Turbine Team 8 Grad Student Mars Madness 1 2% OLVT 2 Rocketry-at-VT 1

Table 9 – Academic Major Academic Major AEDL Team Number Percent (total lab population) AOE 3D PAC 9 47.6% AOE Lunar Rover 4 Mars Madness 5 MSAT 9 NASA SLI 7 OLVT 40 Rocketry-at-VT 22 RockSAT-X 4 SEDs Rocketry 6 Wind Turbine Team 1 BEAM OLVT 1 0.4% Biochemistry Rocketry-at-VT 1 0.4% CEE Mars Madness 1 0.9% Wind Turbine Team 1 ChE Rocketry-at-VT 1 0.9%

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Wind Turbine Team 1 CS Mars Madness 1 4.9% MSAT 5 OLVT 2 Rocketry-at-VT 2 RockSAT-X 1 ECE MSAT 7 12.4% NASA SLI 1 OLVT 6 Rocketry-at-VT 5 RockSAT-X 8 Wind Turbine Team 7 ENGE OLVT 1 1.8% Rocketry-at-VT 3 ISE MSAT 1 0.9% OLVT 1 ME Mars Madness 4 21.3% MSAT 6 NASA SLI 2 OLVT 10 Rocketry-at-VT 6 RockSAT-X 7 SEDs Rocketry 3 Wind Turbine Team 10 MINE MSAT 5 4.4% MSE OLVT 3 2.2% Rocketry-at-VT 1 RockSAT-X 1 Physics OLVT 4 1.8%

Table 10 – Academic Credit Role AEDL Team Number Percent (total lab population) Independent Study 3D PAC 3 14.5% MSAT 7 OLVT 1 Rocketry-at-VT 7 RockSAT-X 3 Wind Turbine Team 12 Senior Design AOE Lunar Rover 4 5.3% MSAT 5 NASA SLI 1 OLVT 2 Undergrad Research 3D PAC 3 8.7% MSAT 6 Rocketry-at-VT 10

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RockSAT-X 1 Volunteer 3D PAC 3 71.3% Mars Madness 11 MSAT 15 NASA SLI 9 OLVT 65 Rocketry-at-VT 24 RockSAT-X 18 SEDs Rocketry 9 Wind Turbine Team 8

Figure 10 shows various ways that students can learn about the AEDL, with most discovering the lab via team information sessions. Figure 11 indicates the square footage allocation for each team and common areas in the AEDL on a percentage basis. Table 11 is a summary of our transfer student population. 11 students, mostly from AOE, served on a variety of AEDL teams in 2020-21 transferring from , Radford University, William and Mary College and the Virginia Community College System (VCCS).

CEED Gobblerfest, 2% O'Show, 1% Online, 2% Word-of- mouth, 14%

Team Info Session, 81%

Figure 10 – “How did you learn about AEDL?”

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Wind Turbine 3DPAC, Conference Machine Shop*, SEDs, 3% Team, 2% 6% Rooms*, 4% 3% RockSAT-X, 2% Offices, 4% Rocketry-at-VT, CAD Lab*, 7% 6%

OLVT, 6%

MSAT, 6% NASA SLI, Hallways/Loading 2% Area*, 43%

Mars Madness, 2%

Figure 11 – Lab Square Footage based on total of 6,500 ft2 *Denotes common-use area.

Table 11 – Transfer-Student Population College or University How did you discover AEDL? Major Team George Mason University Team Info Session AOE OLVT Germanna CC Team Info Session AOE OLVT Germanna CC Team Info Session AOE Rocketry-at-VT Northern Virginia CC Team Info Session AOE 3D PAC Northern Virginia CC Team Info Session CS Mars Madness Northern Virginia CC Team Info Session AOE MSAT Northern Virginia CC Team Info Session AOE RockSAT-X Radford University Team Info Session AOE RockSAT-X Thomas Nelson CC Team Info Session AOE OLVT Virginia Western CC Team Info Session AOE MSAT William and Mary Team Info Session AOE NASA SLI

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Team Lab Access

Students have access to all areas of the AEDL 24/7 via the Hokie Card swipe system. Figure 12 provides a summary of student accessing these areas based a team breakdown. Orbital Launch Vehicle Team (OLVT) and Rocketry-at-VT utilized the lab area the most at 32% and 30%, respectively.

Wind Turbine, 2% SEDs, 5% 3DPAC, 8% MSAT, 16% Rocketry at VT, Mars Madness, 32% 1%

OLVT, 30% NASA SLI, 5%

Figure 12 – Team Access to AEDL (percent card swipes out of 226 students total).

AEDL Advanced Training

Each year, AEDL assistant manager Bob Schoner provides comprehensive training for all rocketry team members in order to obtain Level 1 (L1) rocketry certification. Training consists of face-to- face classes in the areas of rocketry fundamentals and construction and students are required to complete a rocket with solid fuel propulsion that is launched successfully at the Kentland facility. The rocket must return to earth in tack using a deployable parachute system. Figure 13 shows L1 recipients from OLVT and Rocketry-at-VT at Kentland Farm during launch day. Table 12 indicates the students who received L1 training in 2020-21, along with team affiliations. Table 13 is a repeat of Table 12 for the Orbital Launch Vehicle Team. A total of 67 AEDL team members completed L1 certification with three receiving advanced L2 training in 2020-21. L1 certification involves the use of H and I solid and/or hybrid motors. L2 uses two-stage rockets with J, K, and L class motors, having higher impulse values. L3 certification allows for even higher impulse M, N, and O solid or hybrid motors.

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Figure 13 – Left: Rocketry-at-VT during L1 launch session. Right: OLVT L1 launch session. Kevin Engle, center, received his L2 certification on that day.

Table 12 – AEDL Teams Receiving L1 Certifications. Team Student(s) Total NASA SLI Russell London 1 Rocketry-at-VT Sumo Dutta 8 Saumith Gundapuneedi Hanna Kruze Daniel Melillo Ben Piper Salim Roustom London Russell Anthony Spinetta SEDs Ian Burrell 10 Bryce Clegg Elija Gendron Thomas Hepley Reagan Hollar Burrell Ian Kristian Meland Benjamin Radcliffe Inga Schlier John Strader Total 19

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Table 13 – OLVT Team Members Receiving L1 Certifications First Last First Last Aiden Anderson Adam Miller Suyog Aryal Justin Misher Spencer Beery Joseph Morriss Ravonte Campbell Andrew Oliveri Joseph Chinsky Christopher Paoucci Brian Chmiel Divyesh Pendurthi Evan Clark Zachary Pepperl Hailey Craft Jonathan Pokrant Raymond Daniels Shane Pokrifka James Deats Ryan Porzeinski Mark Ebner Reese Preisser James Engle Tyler Rhodes Kevin Engle Kara Roberts Connor Gray Drew Robinson Michael Hancock Adrian Ruvalacaba Susan Hill Magdalena Scaer Adam Hinson Nathan Schicle Trevor Honul Ryan Shaffer Arsam Jafaryzad Kyle Shannon Betsy Juette Kyle Shields David Kennedy Avni Singh Matthew Kramer Brooke Taylor Chase Leuchtmann Daniel Tobias Stephen Merrick Matthew Werner Total 48

Lab Expenditures

AEDL expenditures are shown in Table 14 for 2020-21. All lab expenditures were necessary purchases of COVID 19 related PPE, tooling equipment, and machine maintenance. Funds for all expenditures was provided by the Virginia Tech AOE department.

Table 14 – AEDL Expenditures for 2020-21 Vendor Total Amazon $7,401 Apogee $126 Global $817 Grainger $194 Grizzly $790 Harbor Freight $280 Home Depot $242 Macklin Missile Works $176 McMaster $36 MSC $97

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Soller Composites $137 The Home Depot $160 Woodcraft $194 X-Winder $20 Total $10,670

Conclusion

This annual report for the Advanced Engineering Design Lab includes competition results, student demographics, outreach events, and lab expenditure details. Undergraduates from multiple majors throughout the College of Engineering comprise the teams who design, manufacture and compete top tier projects. Due to the continued COVID 19 concerns some sponsored competition events were canceled, others were held in a virtual format while some were face-to-face. In addition to participating in regional and international events, AEDL teams took part in the College of Engineering’s open house and STEAM Day 2020. Both were virtual events this year due to COVID 19. In spite of unprecedented difficulties, AEDL team members met the challenge of completing project goals and succeeding at sponsored events. Rocketry-at-VT and Wind Turbine Team exceeded expectations with top competition performances at the Space Port America Cup and the Collegiate Wind Competition, respectively. Due to the dedication of these, and all, design team members, the Advanced Engineering Design Lab continues to be an exciting and vibrant place for undergraduate, aerospace inspired, projects in Virginia Tech’s College of Engineering.

[1] Design, Funding, and Development of a Space Launch Vehicle, A. Anderson, M. Baker, P. Blanchette, et. al. Undergraduate Research Paper, Aerospace and Ocean Engineering, Virginia, Tech - 2020

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Appendix A – Comprehensive List of AEDL Students for 2020-21

AEDL Team First Last Major Level Credit? 3D PAC Dylan Adie AOE Senior Volunteer Andrew Bennett AOE Sophomore Volunteer Truman DeWalch AOE Junior Undergrad Research Dalton Grantham AOE Sophomore Independent Study Maddison Hughey AOE Sophomore Volunteer Milad Rowshanbakhtfardian AOE Senior Independent Study Jenith Vijayakumar AOE Sophomore Undergrad Research Jacob Williamson AOE Junior Undergrad Research Kevin Yarnall AOE Junior Independent Study AOE Lunar Rover Julian Bisci AOE Senior Senior Design Dylan Danner AOE Senior Senior Design Samuel Holloway AOE Senior Senior Design Holden McNerney AOE Senior Senior Design Mars Madness Sean Buono ME Junior Volunteer Charlyn Castillo CEE Senior Volunteer Julian Castro AOE Senior Volunteer Shuo Chen ME Grad Student Volunteer Noah Makley AOE Junior Volunteer Evan McKnight CS Senior Volunteer Daniel Megill ME Junior Volunteer Jonathan Munoz AOE Sophomore Volunteer Jack Palmer ME Sophomore Volunteer Rudra Patel AOE Senior Volunteer William Patton AOE Junior Volunteer MSAT Shlok Agarwal ECE Junior Independent Study Samuel Bethge CS Junior Undergrad Research Kashyap Bhatt ME Junior Volunteer Michael Bopp AOE Senior Senior Design Isaac Brumbley ME Freshman Volunteer Vivan Chopra ECE Junior Undergrad Research JULIAN COHEN ME Junior Senior Design Julian Cohen ME Junior Independent Study Rohan Desai ECE Junior Volunteer Anthony DiGregorio AOE Junior Undergrad Research Matthew Emmons ME Junior Undergrad Research Chenming Fan AOE Freshman Volunteer David Fehrle AOE Senior Senior Design Ben Harrington MINE Freshman Volunteer Justin Ingram CS Senior Independent Study Natalie Kakish CS Junior Volunteer Philip Lopez AOE Sophomore Volunteer Anthony Mancini ECE Junior Volunteer Nick McLelland MINE Sophomore Independent Study Jack Michaud ECE Sophomore Volunteer Varun Modak ECE Junior Volunteer Mark Norton AOE Senior Senior Design Jordan Oliver AOE Senior Volunteer Shail Patel ISE Junior Senior Design Avery Rhem MINE Sophomore Independent Study Pranav Sharma CS Senior Volunteer Tanushree Manohar Shinde AOE Junior Independent Study Jackson Underwood ECE Junior Independent Study

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Tom Varner MINE Junior Volunteer Skyler VonDeben AOE Junior Undergrad Research Cole Walton CS Freshman Volunteer Dakota Yannibelli ME Junior Volunteer Zhenghao Zhou MINE Junior Undergrad Research NASA SLI Zachary Belen AOE Sophomore Volunteer Tahj Caines ECE Sophomore Volunteer Joseph Cunningham AOE Senior Senior Design Kristian Meland AOE Sophomore Volunteer Joseph Mensch ME Junior Volunteer Jared Picciano ME Sophomore Volunteer Erin Schiefelbein AOE Sophomore Volunteer Tamim Wadud AOE Sophomore Volunteer Sean Whalen AOE Junior Volunteer Blake Wilhelm AOE Sophomore Volunteer OLVT David Aden MSE Grad Student Volunteer Daniel Alex AOE Junior Volunteer Aidan Anderson AOE Sophomore Volunteer Suyog Aryal AOE Sophomore Volunteer Maya Baker ISE Junior Volunteer Spencer Beery ECE Sophomore Volunteer Patrick Blanchette ENGE Freshman Volunteer Ravonte Campbell AOE Junior Volunteer Kevin Carey AOE Senior Volunteer Brian Chmiel AOE Junior Volunteer Evan Clark ECE Senior Volunteer Hailey Craft AOE Junior Volunteer Raymond Daniels ECE Senior Volunteer James Deats ECE Sophomore Volunteer Ethan Detweiler AOE Junior Volunteer Kevin Engel Physics Senior Volunteer Jacob Gabrilowitz ME Senior Volunteer Connor Gray AOE Sophomore Volunteer Jared Guzman AOE Grad Student Volunteer Michael Hancock AOE Sophomore Independent Study Trevor Hanzel AOE Sophomore Volunteer Susan Hill AOE Junior Volunteer Adam Hinson ME Senior Volunteer Chase Hummel AOE Junior Volunteer Benjamin Jackson AOE Junior Volunteer Arsam Jafaryzad AOE Senior Volunteer Betsy Juette ME Junior Volunteer David Kennedy AOE Junior Volunteer Albert Kodua MSE Junior Volunteer Matthew Kramer ME Junior Volunteer Mark Kukoski BEAM Junior Volunteer John Lacey CS Junior Volunteer Casey Latoski ECE Junior Volunteer Chase Leuchtmann AOE Senior Senior Design Nikolai Long AOE Junior Volunteer Nathan Lowery AOE Junior Volunteer Ryan Maad AOE Sophomore Volunteer Spencer Macturk ME Sophomore Volunteer Suraj Manikandan ME Junior Volunteer Joseph McCabe AOE Junior Volunteer Stephen Merrick AOE Junior Volunteer

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Adam Miller AOE Senior Volunteer Justin Misher ME Sophomore Volunteer Jacob Morriss Physics Senior Volunteer Trevor Mushung AOE Junior Volunteer Andrew Oliveri AOE Junior Volunteer Oskar O'Neal AOE Junior Volunteer Christopher Paolucci AOE Junior Volunteer Divyesh Pendurthi AOE Sophomore Volunteer Zachary Pepperl AOE Sophomore Volunteer Jonathan Pokrant AOE Freshman Volunteer Shane Pokrifka AOE Junior Volunteer Ryan Porzeinski AOE Junior Volunteer Reece Preisser Physics Junior Volunteer Nicholas Rencher MINE Junior Volunteer Tyler Rhodes AOE Freshman Volunteer Kara Roberts AOE Sophomore Volunteer Andrew Robinson Physics Junior Volunteer David Rowson CS Sophomore Volunteer Adrian Ruvalcaba ECE Junior Volunteer Magdalena Scaer AOE Freshman Volunteer Ryan Shaffer AOE Junior Volunteer Kyle Shannon ME Junior Volunteer Kyle Shields ME Sophomore Volunteer Avni Singh AOE Junior Volunteer Brooke Taylor AOE Sophomore Volunteer Daniel Tobias ME Senior Volunteer Ivan Wu AOE Senior Senior Design Rocketry-at-VT Trevor Bondi ME Senior Independent Study Jacob Bonilla AOE Senior Volunteer Paul Broome ENGE Freshman Volunteer Abinay Brown AOE Sophomore Volunteer Anna Carnahan MSE Sophomore Undergrad Research Pierce Carver ME Sophomore Volunteer Neha Chinthapatla AOE Sophomore Independent Study Zachary Collins ME Sophomore Volunteer Anikait Das AOE Freshman Volunteer Jaison Dasika ME Sophomore Volunteer Malik Deslauriers AOE Freshman Undergrad Research Jacob Di Girolamo ECE Sophomore Volunteer Soumodeep Dutta AOE Senior Undergrad Research John Fiorini ECE Sophomore Volunteer Joseph Foster AOE Grad Student Volunteer Ria Garg AOE Sophomore Undergrad Research Jack Griggs AOE Junior Volunteer Saumith Gundapuneedi AOE Freshman Volunteer George Haug AOE Sophomore Undergrad Research Zachary Hoelscher AOE Junior Volunteer Sasha Holt CS Sophomore Undergrad Research Ethan Husmann AOE Sophomore Volunteer Will Katz ECE Sophomore Volunteer Mustafa Khan ENGE Sophomore Volunteer Hanna Kruse AOE Sophomore Undergrad Research Daniel Melillo AOE Senior Volunteer Gabe Mills ECE Freshman Volunteer Benjamin Piper AOE Sophomore Undergrad Research Taylor Pippen ME Sophomore Independent Study

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Michael Punaro ECE Sophomore Undergrad Research Emma Putnam Biochemistry Senior Volunteer Jocelyn Riet ChE Senior Volunteer Binay Rijal CS Sophomore Independent Study Henry Roberts AOE Senior Volunteer Salim Roustom AOE Senior Volunteer London Russell ME Senior Independent Study Anthony Spinetta ENGE Freshman Volunteer Christopher Tomko AOE Senior Independent Study Reilly Towns AOE Sophomore Undergrad Research Megan Wilkie AOE Sophomore Volunteer Alex Willis AOE Senior Independent Study RockSAT-X Beyonce Andrades ECE Freshman Volunteer Roshen Arun ME Sophomore Volunteer Callie Brown AOE Junior Volunteer Spencer Buebel ECE Senior Undergrad Research Gendron Elijah MSE Junior Volunteer Patrick D Flynn ECE Senior Independent Study Chris Hong ME Sophomore Volunteer Charles Krzyzewski ECE Junior Volunteer Kevin Lizarazu-Ampuero ECE Sophomore Volunteer David Lu ME Junior Volunteer Ben Masters ME Junior Volunteer Christopher Mattson AOE Senior Volunteer Kyle Mergler ME Junior Volunteer Kathryn Robertson ECE Junior Independent Study Hunain Ali Shamsi ECE Junior Independent Study Chris Sorenson AOE Junior Volunteer Surabhi Srivastava AOE Senior Volunteer Daniel Stover ECE Sophomore Volunteer Eric Williams ME Junior Volunteer Stephen Yang CS Senior Volunteer Alexander Zapata ME Sophomore Volunteer SEDs Rocketry Ian Burrell ME Senior Volunteer Shreya Chandramouli AOE Senior Volunteer Bryce Clegg AOE Senior Volunteer Reagan Hollar ME Sophomore Volunteer Thomas Kepley AOE Sophomore Volunteer Benjamin Radcliffe AOE Sophomore Volunteer Inga Schlier AOE Senior Volunteer John Strader ME Sophomore Volunteer Raeven Waters AOE Senior Volunteer Wind Turbine Team Benjamin Alden ECE Senior Independent Study Brady Alexander ECE Sophomore Volunteer Alvaro Armaza CEE Senior Independent Study Hayley Capilitan ME Junior Independent Study Gavin Doering ECE Senior Independent Study Isaac Edwards ME Junior Independent Study Kaley Foulks ME Sophomore Volunteer William Hall ECE Senior Independent Study Lauren Hall ME Senior Independent Study Shane Johnson ECE Sophomore Volunteer Kaishin Kato ME Junior Independent Study Garrett Kemmerly ME Senior Volunteer James Lin ECE Sophomore Volunteer Bryan Meldrum ME Senior Independent Study

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Aaron Miller ME Sophomore Volunteer Olivia Moldoveanu ECE Junior Volunteer Ryan Oosterhuis ME Junior Independent Study Om Shah ME Junior Independent Study Elizabeth Spicer ChE Senior Independent Study Sean Zylich AOE Sophomore Volunteer

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Appendix B – Rocketry-at-VT Competition Results for 2020-21

Poster Technical Session Design Design Final University or College Report Video Competency Decisions Total Ranking , Twin Cities 375 194 145 143 481 1 Norwegian University of Science and Technology 381 179 148 145 471 2 The 369 191 141 144 477 3 Virginia Tech 381 173 137 142 452 4 Monash University 389 192 144 145 482 5 University of Sydney 353 188 143 140 470 6 Poznan University of Technology 326 195 147 149 490 7 McGill University 360 175 138 133 445 8 Case Western Reserve University 358 170 136 135 440 9 356 178 131 126 434 10 University of Minnesota, Duluth 342 169 140 137 445 11 361 172 122 127 421 12 University of Waterloo 317 183 139 144 465 13 California State Polytechnic University, Pomona 355 161 127 130 418 14 354 175 139 102 416 15 Manipal Institute of Technology, Manipal 340 173 125 128 426 16 Oregon State University 338 161 135 128 425 17 University of Samsun 356 161 121 119 401 18 AGH University of Science and Technology 325 170 134 126 431 19 Aristotle University of Thessaloniki 316 188 116 135 438 20 Ecole Polytechnique Fédérale de Lausanne 320 163 138 130 431 21 Dearborn 330 167 128 124 418 22 Cukurova University 349 153 124 122 399 23 Wroclaw University of Science and Technology 346 147 127 128 402 24 Institute of Technology (aka 141) 280 183 145 138 465 25 State University of New York at Buffalo 363 132 120 126 378 26 Carleton University 335 192 119 135 446 27 Missouri University of Science and Technology 361 148 110 108 367 28 State University 304 169 126 126 421 29 University of Manitoba 311 166 123 120 408 30 Eidgenössische Technische Hochschule Zürich 256 186 140 135 460 31 , Berkeley 302 160 126 126 412 32 Sinhgad Technical Education Society, Pune 357 145 98 107 350 33 University of Illinois, Urbana-Champaign 355 138 107 102 346 34 École de Technologie Supérieure 312 159 119 109 387 35 George Washington University 353 135 94 108 337 36 University of Western Australia 363 121 128 133 381 37 Rochester Institute of Technology 288 168 130 135 433 38 University of Western Macedonia 298 160 108 115 383 39 Lehigh University 307 171 94 94 358 40 University of Maryland - College Park 355 120 98 80 298 41 Florida International University 287 150 122 87 358 42 Brigham Young University 234 158 133 114 404 43 Instituto Tecnológico de Aeronáutica 324 140 100 72 312 44 Federal University of Rio de Janeiro (UFRJ) 265 148 106 111 364 45 Polytechnique Montreal 295 135 128 109 372 46 University of São Paulo 286 153 94 94 340 47

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West Virginia University 298 98 113 115 325 48 Tecnológico de Monterrey, Campus Monterrey 271 133 112 106 351 49 Embry-Riddle Aeronautical University, Daytona 212 160 125 123 408 50 Purdue Space Program Solids 277 158 119 104 381 51 Vellore Institute of Technology 301 150 97 108 355 52 Ryerson University 261 197 106 106 409 53 259 136 100 97 333 54 University Djillali Liabes Sidi Bel Abbes 215 141 114 117 372 55 California State University, Fullerton 303 108 108 68 283 56 University of Texas at San Antonio 272 118 103 93 313 57 University of Wisconsin-Platteville 219 147 119 98 365 58 150 211 107 111 428 59 BITS Pilani, Hyderabad Campus 214 151 106 104 361 60 University of - Knoxville 246 105 107 116 328 61 Military Technical College 187 143 133 106 381 62 Gdańsk University of Technology 237 122 88 93 303 63 University of Hawaii, Honolulu 170 148 123 92 362 64 Kathmandu University 221 98 88 88 273 65 University of California, Los Angeles (aka 77) 351 40 63 78 180 66 127 145 113 108 366 67 National University of Science and Technology 222 83 78 85 245 68 292 0 0 0 0 69 University of Sheffield 298 0 0 0 0 70 Sheffield Hallam University 247 0 0 0 0 71 Lenior Rhyne University 242 0 0 0 0 72 The University of Akron 227 0 0 0 0 73 Universidad Autónoma de Baja California 195 0 0 0 0 74 Michigan State University 186 0 0 0 0 75 University of Texas at Arlington 0 165 0 0 165 76

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Appendix C – ISE Senior Design Research on AEDL Optimization and Expansion

The following undergraduate research report was submitted for partial fulfillment of ISE 4005, 4006 for the 2020-21 academic year. This report is a comprehensive study of potential lab optimization and expansion into a 14,000 sq. ft. adjacent rental space located at the AEDL.

VTISE-44-AEDL Advanced Engineering Design Lab Optimization and Expansion

Brittany Gerald Sid Komaragiri Josh Murray Rachel Rosenbaum Grado Department of Grado Department of Grado Department of Grado Department of Industrial and Systems Industrial and Systems Industrial and Systems Industrial and Systems Engineering Engineering Engineering Engineering Virginia Tech Virginia Tech Virginia Tech Virginia Tech Blacksburg, VA USA Blacksburg, VA USA Blacksburg, VA USA Blacksburg, VA USA [email protected] [email protected] [email protected] [email protected]

Faculty Advisor: Ken Client Contacts: Dewey Bob Schoner, Harmon, [email protected] Spangler, PE (editor), [email protected] [email protected]

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Virginia Tech’s Advanced Engineering Design Lab (AEDL) is a new facility that houses 11 undergraduate design teams in the areas of rocketry, drone technology, aircraft design and turbine energy in 6,500 sq. ft. of a 20,800 sq. ft. off- campus facility. By optimizing currently available space and creating a methodology to utilize space in the future, the design lab can expand into an available adjacent area as requirements evolve. Optimizing existing space for AEDL teams, designing expanded space to accommodate new design teams, and creating a method to gather feedback from stakeholders addressing resources, builds a foundation for the success of students that desire hands-on experience. As a result of this project, the client can expect an increase in investment capital, capacity, and utilization. In addition, increase in the competitiveness of Virginia Tech design teams and in the future employment prospects of AEDL students is an expected outcome.

I. Introduction Virginia Tech’s AEDL is a joint venture between Aerospace and Ocean Engineering (AOE) and the College of Engineering (COE). AOE provides 100% funding for space rental and equipment procurement and the COE provides salaries for a part-time manager and full-time assistant manager. Figure 1 is the client’s (management’s) current layout of the space. Each AEDL team is allocated a specific work cell, varying in size. Additionally, the AEDL includes a machine shop, computer-aided design (CAD) lab, two conference rooms, and a loading area. The machine shop includes equipment that teams use to cut, measure, and epoxy various materials. The CAD lab is a designated space with networked computers that allows students to perform CAD, FEA and CFD tasks and to use other software, as needed. The facility has a loading area, which provides teams easier access to transport materials and equipment.

Figure 1 - Current AEDL Layout

The AEDL has lab space and equipment for engineering design teams to use in preparation for competitions and outreach events that occur each academic year. This newly acquired lab (Cir. 2019) needs improvements in general layout, machinery, equipment, and tooling to provide the best experience possible for current and future teams. Project goals include optimizing current available space and creating a resource management methodology. This methodology will be used by the client to allocate resources in future years as the facility expands and requirements evolve. Currently, teams occupying lab space specialize in aerospace engineering but students from other majors may serve on any team (Table 1) [1]. There is ample additional space within the building adjacent to the current facility that will become available in June, 2021. An in-depth analysis of current and future square footage use will provide insight for stakeholders that supports the idea of lab expansion to include additional Virginia Tech engineering teams. The overriding goal of optimization and expansion of the AEDL is to increase the competitiveness of Virginia Tech undergraduate design teams while impacting as many students as possible. The necessity to address the availability of space for undergraduate project teams cannot be understated as student populations continue to grow in engineering and other STEM related fields [2].

Table 1 – AEDL Team Enrollment for 2020-21 AEDL Team Enrollment %AOE Mars Subsurface Analysis Team 32 100% Mars Madness 12 42% NASA SLI 11 64% OLVT 67 60% Rocketry@VT 40 100% RockSAT-X 20 25% SEDs Rocketry 9 100% Wind Turbine Team 20 5% 3DPAC 9 100% AUVSI 0 0 inVenTs Rocketry 0 0 Total: 220 49%

II. Opportunity Statement

A management method is created by the ISE senior design team to improve utilization of current materials, tools, and equipment. Surveys are created for current and future customers (teams) so that the clients may document what resources are needed to increase lab effectiveness. Lab managers Dewey Spangler and Bob Schoner assist AOE teams with yearly competitions and outreach events and provided the ISE team necessary deliverables to complete before redesigning the space. Specific deliverables are: detailed CAD drawings of the current AEDL building space (including equipment), CAD drawings of existing AEDL work cells and non-permanent structures, CAD drawings of the expansion space, and cost estimates for equipment build-out in the redesigned and expanded space. The proposed area of expansion is occupied by another tenant until May 2021 and Virginia Tech is considering leasing this space for future undergraduate teams, as resources become available. Creating a carefully thought out expansion plan ahead of time will ensure that the AEDL can provide the best experience for new teams. Out of project scope are restrictions on student numbers due to university COVID 19 guidelines. Also, the team is not modifying existing, permanent structures. Only partition (movable) bay walls in the current space are being considered. Also, the team will not be focusing on modifying electrical power in the facility.

III. Solution Approach

The design methodology that the ISE team chose is the DMADV methodology. This methodology - to define, measure, analyze, design, and verify - matched the teams’ timeline. Creating a method for managing lab resources is a new process since there is no current, viable, assessment procedure. In order to design a layout for optimal lab expansion, thorough assessment of resource use in the lab is necessary. The ISE team consulted with lab management in order to accurately define project goals. Once the deliverables and client expectations were understood, the team was able to move forward with measurements of current and expanded lab spaces. After measurements from the work cells, the machine shop, the CAD lab and conference rooms were completed, the ISE team conducted interviews with three AEDL design teams. These interviews are described in detail in the Comparison of Alternative Solutions section of this report. The interviews served as a way to understand details of how space is currently used and to understanding customers’ needs. Design concepts were discussed during the interviews to compare each team's specific needs. After collecting data from the first three teams, a survey was prepared and distributed to all AEDL teams. While compiling feedback, the ISE team completed a 2D CAD layout of existing infrastructure including movable equipment, furniture and tools. Measurements of the potential expansion space of the building were also completed. After CAD drawings were completed, the ISE team explored cost estimates for new equipment.

Comparison of Alternative Solutions

The ISE team considered four concepts for the redesigned AEDL. These alternative designs focused on utilizing vertical and horizontal space, and optimizing the accessibility of electrical outlets and bay storage space. Note: utilizing vertical space refers to the ability to move and store tall equipment, such as rocket and aircraft fuselages. Based on conversations with the clients, it was decided that NASA Student Launch Initiative (NASA SLI), Orbital

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Launch Vehicle Team (OLVT), and the 3D Printed Aircraft Team (3DPAC) would be interviewed in depth. These teams were selected due to their strong presence in the AEDL and two of the three teams have memberships that include students from across the college of engineering (Table 1) [1]. The purpose of these interviews was to determine whether the four mentioned design concepts would be applicable in a new lab layout. Based on feedback, the ISE team constructed Table 2 to decide which concepts would be considered.

Table 2 - Design Concept Decision Matrix Vertical Horizontal Electrical Storage Space Space Outlets Space Need for Change No Yes No Yes Feasibility No Yes No Yes Compliance with requirements Yes Yes No Yes

For the “Need for Change” item (row 1) a “yes” indicates that all three teams felt that a change, such as storage space, would be beneficial. Accordingly, there is a need to also change horizontal space, while there is no need to address the accessibility of electrical outlets or to optimize vertical space. Team responses to “Feasibility” and “Compliance of Requirements” were similar. After establishing design criteria, the ISE team proceeded to design several layout options. After initial interviews with NASA SLI, OLVT, and 3DPAC the ISE team distributed a team-lead survey to all AEDL leadership working in the facility. A second survey was distributed to all Virginia Tech engineering departments. Based on survey feedback (Appendixes A and B) the ISE team developed a plan for AEDL optimization and expansion. The ISE team also worked with the client to establish equipment costs associated with optimization and expansion reflected in the feedback from each survey. (Appendix C).

IV. Results

Responses from both surveys indicate, not surprisingly, that there is a dire need for workspace for undergraduate student design teams. The ISE team received feedback from over 25 project teams from 5 of 14 engineering departments. One department, mechanical engineering, did not reply to the survey. This department requires that all senior design teams (over 40 in number) construct a viable working prototype that must be presented at a year-end design forum. Considering that mechanical engineering is the largest department in the college, the need for space is even more pressing. While the AEDL is predominantly an aerospace engineering lab, results from the engineering department survey indicates that there is a potential to introduce 18 new undergraduate teams spanning five to six additional departments. The specific number of teams needing workspace by department is shown in Figure 2.

Figure 2 - VT Design Teams Requesting Workspace

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From Appendix A, the amount of new space requested by COE departments totaled 15,000 ft2. This corresponds well with the 14,500 ft2 of available building expansion space. Of the 11 undergraduate design teams currently in the AEDL, 8 responded to the team-lead survey. Question 6 of the survey indicated that 63% of teams performed work away from the AEDL that could be done on site. Question 18 focused on what would incentivize students to work more in the lab. 63% respondents indicated that they would return if additional equipment were available, 50% said that having the AEDL moved to the main campus would encourage more participation, and 25% said that having more space would encourage participation. Perhaps in the future on-campus spaces may become available but currently this is not a viable option. Figure 3 recaps responses for Question 18.

Figure 3 - I would work more in the AEDL if...

Question 12 addresses the need for additional equipment. All teams responded that existing ventilation at the AEDL is inadequate, 88% expressed a need for a CNC waterjet and 3D printer, and 50% expressed a need for a cutter and CNC lathe. Figure 4 shows the results of this survey question.

Figure 4 - Equipment Needs for Current AEDL Teams

Questions 13 and 14 address specifics concerning the need for 3D printing technology. The ISE team polled teams on the three most important requirements for a 3D printer: large build volume, high resolution, and the ability to accommodate different material types. From this input the ISE team selected three 3D printer models as shown in Appendix C. Additional equipment cost estimates, at three price levels, are shown in Appendix C. Table 3 summarizes these costs: low estimate = $40,800, medium estimate = $97,000, and a high estimate = $161,700. The recommendations of which equipment

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to purchase for the lab is included in the Future Recommendations section of this report. Figure 5 shows current AEDL infrastructure and equipment, including machines, storage and tables (green). The available expansion space is shown in magenta.

Figure 5 - Current AEDL (green) and proposed expansion (magenta). A and B denote high bay door locations.

Table 3 - Cost Estimates For Build Out Low Medium High Cost Cost Cost CNC $8,000 $28,500 $56,800 Machine/Waterjet Laser Cutter $4,700 $17,000 $27,000 3D Printer $1,900 $4,000 $7,900 CNC Lathe $26,200 $47,500 $70,000 Total: $40,800 $97,000 $161,700

V. Impact of Results Increase in investment capital results from team sponsorships anticipated with the expansion of the lab. Design teams pay $8000 per year to lease one bay. Expected increases in team sponsorships are based on support provided to Ware Lab teams in 2018 (Table 4) [3]. The ISE team projected that the average yearly sponsorship for larger teams (BOLT, Formula SAE, Baja SAE, HEVT) is $68,000 and $16,000 for smaller teams. With the addition of ten new teams, $160,000 to $680,000 will be potentially gained in new sponsorships. Out of this investment capital, initial and recurring equipment/material costs will be deducted, as necessary.

Table 4 - Ware Lab 2018 Team Sponsorship Team Corporate Private Virginia Total Tech Astrobotics $29,000 $0 $6,600 $35,600 Baja SAE $29,000 $5,000 $10,700 $44,700 BOLT $30,000 $0 $4,800 $34,800 Design Build Fly $10,000 $0 $4,500 $14,500 Formula SAE $145,000 $3,000 $10,400 $158,400

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Hybrid Electric $26,700 $2,000 $7,420 $36,100 Vehicle Human Powered Sub $8,000 $0 $9,700 $17,700 SailBOT $0 $0 $2,400 $2,400 Steel Bridge Team $6,800 $190 $900 $7,900 Total: $284,500 $10,200 $64,770 $359,000

The resulting lab expansion and equipment upgrade effectively increases capital investment, while also increasing capacity and utilization, positively impacting the project and outreach activities of each design team. The team-lead survey provides AEDL students a tool to communicate resource needs with lab management. With an increase in teams, AEDL has the ability to participate in more sponsored competition events and to host additional outreach events. Outreach is important because of Virginia Tech’s strong focus on STEM related activities. Involvement in outreach allows team members to articulate project specifics to K12 groups, industry leaders, and university officials. As students gain confidence in presenting their ideas, they grow in their personal understanding of engineering principles and are more competitive in their chosen fields.

VI. Future Recommendations ISE Team 44-AEDL recommends that the clients continue using the department and team-lead surveys developed in this study to assess future resource needs. Also, Figures 6 illustrates a viable path towards optimization and expansion of lab facility into adjacent areas of the building. The expansion includes the relocation of the machine shop to a larger, more accessible location and the addition of a material prep space for paint, epoxy, and carbon fiber related work. From the team-lead survey, AEDL teams expressed a need for a larger conference room and an area for locked storage. These areas are included in the expansion plan. The additional space also includes more administrative offices and an electronics cleanroom (where the machine shop currently exists). Other rooms in the expanded space could be used for meeting/computer rooms and project bays for smaller teams. The ISE team further suggests moving four current AEDL teams (3DPAC, NASA SLI, OLVT, and Rocketry@VT) to larger bays in the expanded high-bay area. RockSAT@VT and SEDs would remain in the current space but would occupy reconfigured bay areas having more square footage (Figure 6, Table 5).

Figure 6 - AEDL Expansion (see Table 5 for key).

Table 5 - AEDL Expansion Areas in Square Feet. Item (Figure 6) Description Area (sq. ft) A High Bay Door NA B High Bay Door NA

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C Electronics Clean Room 220 D 3D Printer Lab 380 E Office 130 F Conference Room 225 G CAD Lab 353 H Reconfigured Bays 450 I Bulk Storage 300 Machine Shop (relocated) 1250 Material Prep Area 1250 1 through 4 Medium Project Bays 500 x 4 5, 6, 7, 10, 11 ,12 Small Project Bays 260 x 6 8,9 Large Project Bays 660 x 4 Total Bay/Project Areas: 10,750 sq. ft

Based on consultation with the client and a study of responses from the department and team-lead surveys the ISE team presented three levels of equipment expenditure shown in Appendix C. In order to address pressing needs in the area of machining and manufacturing and to still remain cost effective the ISE team recommends that the client consider the medium- priced option.

VII. Conclusion The Advanced Engineering Design Lab is a new, experimental project facility that hosts 11 aerospace inspired undergraduate teams. Virginia Tech’s ISE Team 44-AEDL has provided AEDL lab management with a method to gather information on future resource requirements, a plan for optimization of the current AEDL space, and a plan for eventual lab expansion into adjacent building space. Optimization and expansion specifics are presented in this report in the form of detailed CAD drawings of the entire building complex. Optimization and expansion plans are based on consultation with AEDL lab management (clients) and on in-depth assessment of current and future stockholders (project teams) via two surveys developed by the ISE team. The surveys provide necessary feedback on how current resources should be used and how facility expansion should proceed. As U.S. populations of college-aged students needing STEM education continues to grow, optimization and expansion of project team facilities, like the AEDL, becomes more pressing. Moving forward with the ISE team’s recommendations will allow Virginia Tech to provide a more fulfilling experience for students desiring a strong hands-on component to their engineering education. Being a part of the AEDL allows students the opportunity to participate in regional and national sponsored events and to keenly apply engineering skills in real time in an exciting competitive setting.

References: 1- AEDL Annual Report 2020-21, D. Spangler, Virginia Tech College of Engineering. 2- , National Science Foundation, Science and Engineering Indicators 2018 (https://nsf.gov/statistics/2018/nsb20181/report/sections/higher-education-in-science-and-engineering/undergraduate-education-enrollment- and-degrees-in-the-united-states). 3- Ware Lab Annual Report 2018-19, D. Spangler, Virginia Tech College of Engineering.

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Appendix A – Engineering Department Survey Responses Engineering Department/ Indicate the name(s) of Does this team(s) What are the team's What are the team's Contact senior design or participate in a special material and space needs undergraduate projects regional or national equipment needs. (approximate square that require building a competition? If so, footage)? proof-of-concept or a what is the name of final working the competition? prototype.

2 Engineering Education, • Autoplane Archimedes ● ASTRA: fiberglass, 1000 ft Contact: David Gray, undergraduate Society ASTRA foam cutting (CNC) [email protected] competes in NASA research (UGR) ● Autoplane: hot foam Micro Next-G • NESTAI UGR cutter, soldering

• Heat Switch UGR station and • Archimedes ventilation ASTRA student ● Heat Switch: DC organization power supplies, • Brain Controlled thermal chamber (- Prosthetics UGR 40C to 100C), • Courtesy Horn electromagnet, 3D UGR printing

● Brain Control: Oscilloscope, 3D printing, low temp oven, basic woodworking (router, drill press), sockets, wrenches Civil and Environmental American Institute of American Institute of MIG welder, electrical and 1500 ft2 Engineering, Contact: Matt Steel Construction Steel Construction battery-operated hand Eatherton, [email protected] (AISC) Student Steel (AISC) Student Steel tools, grinders Bridge Competition Bridge Competition (regional and national) Civil and Environmental American Society of American Society of Styrofoam and plywood 1500 ft2 Engineering, Contact: Civil Engineers (ASCE) Civil Engineers for concrete canoe David Mokarem, Student Concrete Canoe (ASCE) Student formwork, CNC router, [email protected] Competition. Concrete Canoe electrical and battery- Competition (regional operated hand tools, and national) concrete mixer, wet burlap, plastic, humidifier Electrical and Computer 500 ft2 • IEEE Robotics • IEEE SouthCon Machining equipment, 3D Engineering, Contact: Scot Student Robotics • NASA Big Idea printer, electrical and Ransbottom, Competition • NASA CubeSat battery-operated hand [email protected] • NASA BigIdea tools, grinders • Robot, drone, UAV projects • Interdisciplinary Projects (2-5/year) 2 Aerospace and Ocean Virginia Tech Human National International ● drill press 2000 ft Engineering, Christine Powered Submarine Submarine Race (ISR) ● fume hood Gilbert, [email protected] Team ● composite particulate filter ● vacuum former ● welding equipment ● CNC lathe and mill ● band saw ● waterjet ● wetsuits ● SCUBA tanks ● regulators ● hand power tools ● vacuum pumps

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● 3D Printer ● carbon fiber ● fiberglass ● epoxy resin ● aluminum ● stainless steel ● plexiglass ● silicone rubber ● casting resin ● ABS and PLA ● insulation foam ● vacuum bagging Aerospace and Ocean Wind Turbine Team @ DOE Collegiate Wind ● laser cutter Engineering, Contact: Matt Virginia Tech Competition 500 ft2 ● CNC lathe and mill Kuester, [email protected] ● composite station (with fume hood) ● drill press ● bandsaw ● electronics testing area ● PCB printer ● 3D printer 2 Biomedical Engineering ● e-NABLE at ● Various regional ● 3D printer 2000 ft and Mechanics, Contact: Virginia Tech and national ● resin Sara Arena, [email protected] ● i-MADE Design-a- competitions ● hand tools thon ● drill press Bioactivity at ● ● sander Virginia Tech ● laser cutter ● bandsaw ● mitre saw ● CNC lathe/mill/engraver ● vacuum forming ● sewing machine ● Injection molding equipment 2 Industrial and Systems ● AmeriCare Plus – ● ● electrical workbench 2000 ft Engineering, Contact: Matt Customized (FutureHAUS) with soldering Earnest, [email protected] Wheelchair ● NASA Robotic station

● Astrobotics Mining ● magnifying lighted ● FutureHAUS Competition glass (Astrobotics) ● AmeriCare Plus – ● bandsaw

All Terrain Walker ● drill press ● Boeing – ● router Advanced ● oxyacetylene Technologies welding Improved ● jig saw, hammers, Processes pliers, wrenches, ● RIZE – The Future sockets, wire cutters, of Work utility knife, screwdrivers, tin snips ● polymer cartridges for 3D printer

2 Biomedical Engineering Interdisciplinary None currently ● student workbenches 2500 ft and Mechanics, Contact: (BEAM, ME, ISE, and ● standard tool boxes ECE) senior design

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Robin Queen, ● 3D printers [email protected] ● CNC lathe

● CNC mill 2 Mining and Minerals The Boring Competition The Boring Company’s ● concrete 1500 ft Engineering, Contact: Team at Virginia Tech, “Not-a-Boring ● machining Taylor Ransford, aka - The Diggeridoos Competition” equipment [email protected] ● welder Total requested square 15,000 ft2 footage:

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Appendix B – AEDL Team-Lead Survey Responses

1. Did you have any issues moving into the work cell regarding any large equipment/ materials?

● OLVT: We have some very large items that would benefit from a separate storage room ● Rocketry at VT: None that were memorable. Although, it was somewhat difficult to move things like storage cabinets around corners. ● RockSAT-X: No ● MSAT: No ● NASA SLI: No ● Mars Madness: No ● 3DPAC: Yes, moving tables, storage, and doors was difficult for two reasons. The front door setup makes it difficult to open both doors and swipe in. The hallways are somewhat narrow and it was difficult to navigate into our room specifically. ● Wind Turbine Team at VT: No, we can easily carry most of our parts and equipment into the lab.

2. If VT decides to lease more space in the building, would you be willing to relocate to space that is now part of the print shop?

● OLVT: Yes if that means we get more room ● Rocketry at VT: Yes! ● RockSAT-X: Yes, if that meant moving to a larger bay ● MSAT: Yes, willing to relocate ● NASA SLI: Yes. Absolutely. ● Mars Madness: Yes ● 3DPAC: I'm content with the current position, but would be willing to relocate if we were guaranteed more space and the same resources. ● Wind Turbine Team at VT: Yes, that would be possible for our team.

3. Does your team have enough horizontal workspace (in square feet) in your bay?

● OLVT: It is good for now but as projects get more ambitious more room will be needed ● Rocketry at VT: Relatively so, yes. ● RockSAT-X: Currently yes, but with a growing team and when COVID restrictions loosen this will become a no. ● MSAT: Yes ● NASA SLI: (No*) This year we did due to many members leaving. But next year the team will be much larger and have more equipment. ● Mars Madness: No ● 3DPAC: No, we need more tables or workable space. ● Wind Turbine Team at VT: We do have enough horizontal space in our bay, we just need to organize it and make use of some space that’s blocked off by old, unused parts. However, if it is possible to get more space we would be able to use that to our advantage.

4. Does your team have enough horizontal workspace (in square feet) in the common areas (machine shop, CAD lab)?

● OLVT: Yes ● Rocketry at VT: I think the machine shop could definitely use more space, especially if it is to expand. The CAD Lab isn't completely functional yet so it's hard to comment on this. ● RockSAT-X: Yes ● MSAT: Yes ● NASA SLI: It is a little tight when everyone is in the machine shop ● Mars Madness: Yes ● 3DPAC: Yes ● Wind Turbine Team at VT: There’s enough open space in the common areas, but having more tables and chairs/stools (stools might be better), in the common areas would be really helpful.

5. What are your top 3 needs, concerns, or barriers?

● OLVT: 3D Printer, Mitre Saw, Ventilation in bay and machine shop; Lathe, CNC Machine ● Rocketry at VT: ● RockSAT-X: 1) limited people in the bay due to COVID, 2) limited storage space, 3) limited tools in the machine shop ● MSAT: Public transport to AEDL, sign out front saying AEDL, parking lot is too small ● NASA SLI: NEED: Place to store fuel grains. No computer cutting machine (laser cutter || waterjet || CNC machine). Not enough composite manufacturing tools. ● Mars Madness: If a larger space is acquired it will be helpful as the size of the rover is 5ftx5ftx5ft which is hard to fit currently.

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● 3DPAC: Needs: 3D Printer. Concerns: AOE Department. ● Wind Turbine Team at VT: 1.Currently the lab lacks machinery that allows us to be precise with our machining. (CNC, Lathes, similar machining tech would be so helpful.) 2.Having scrap materials available to use instead of being thrown away would be nice. 3.Not enough seating around in common areas/our bay.

6. Are you doing work on your project outside of the AEDL?

● OLVT: No, except when we actually go out to launch one of our rockets ● Rocketry at VT: Yes due to COVID ● RockSAT-X: Yes ● MSAT: Painting, cutting fiberglass, drilling experiments (covered concrete test area would be helpful) ● NASA SLI: Yes. ● Mars Madness: No ● 3DPAC: Yes, we don't have a 3D Printer so have to print on private machines at our own cost ● Wind Turbine Team at VT: Not really, other than testing in the wind tunnel

7. Does your team need a conference room space for team meetings? If so, are the current conference rooms big enough or would your team need a larger conference room? *Assuming no COVID restrictions

● OLVT: None of the conference rooms would accommodate our entire team, we have ~100 people; That would be nice, there is currently not a room big enough to accommodate all 85 of our members ● Rocketry at VT: Yes. Current conference rooms are large enough for leadership meetings. It would be really nice if there were larger rooms (50 person+) for global body meetings. We usually use classrooms for this though. ● RockSAT-X: No conference room space needed ● MSAT: No, not used very often ● NASA SLI: We do need conference rooms. 8 people would be great. ● Mars Madness: The current conference rooms are big enough for our team ● 3DPAC: No, we're fine ● Wind Turbine Team at VT: No

8. Does your team need extra storage space? If so, please be specific. What kind of storage space are you in need of, and where? (e.g. rocket storage, tool storage, equipment storage, space under the workbench, overhead storage, etc.)

● OLVT: Yes, for miscellaneous items such as test stands that get used rarely but take up large amounts of space; Yes, for large items that we only use occasionally like recovery test stands ● Rocketry at VT: The ability to use wall space would address a serious need. Overhead storage I think covers this. Soon we will need more room to store former rockets or other older projects. ● RockSAT-X: Yes, and enclosed cabinet would be helpful for storing parts / old payloads out of the way ● MSAT: Metal pegboard for adjustable storage of equipment ● NASA SLI: Fuel Grain storage. Next year we will need more horizontal space. ● Mars Madness: No ● 3DPAC: Yes, lockable shelving. Vertical storage space would be useful for storing experimental aircraft with the smallest horizontal footprint. Overhead storage or shelving to store additional components/prints and free up tables. ● Wind Turbine Team at VT: Having some extra storage space would be nice (overhead or wall storage sounds great for some larger pieces). We would also love to have some sort of shelving for tools and smaller pieces.

9. Does your team have a competition this year? If so, is it virtual or in person? What is the date?

● OLVT: No competition, but we do have launches and testing to do throughout the semester; We do not participate in competitions ● Rocketry at VT: Yes, Spaceport America Cup. Virtual. ● RockSAT-X: Yes, Sounding rocket launch August 9 ● MSAT: Yes, in person. Date TBD ● NASA SLI: We were going to but we do not. ● Mars Madness: Yes it is virtual. Mar 25, 2021 is the date of the virtual submission deadline. ● 3DPAC: Yes, in person. July 9th-11th ● Wind Turbine Team at VT: Yes, it is virtual. Early June.

10. What machines/equipment (if any) do you use in your bay throughout the year?

● OLVT: Handheld tools, drill press, etc…; Power tools ● Rocketry at VT: Hand tools, bench grinder, angle grinder, soldering station, 3D Printer, power tools (drill, sawzaw), dremel ● RockSAT-X: Oscilloscope, Power supply, multimeter, soldering station, hot air rework station, hand tools, drill, 3D printer ● MSAT: Miter saw, thermometer, power tools ● NASA SLI: Drills, allen keys, screwdrivers, soldering iron, wiring tools.

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● Mars Madness: Hammers, Drills, Screwdrivers are the primary equipment. ● 3DPAC: Solder station, hot glue gun, pending Modix Big 60 3D Printer ● Wind Turbine Team at VT: Dremel, power drill

11. What machines/equipment (if any) do you use in the machine shop throughout the year?

● OLVT: All of them ● Rocketry at VT: Bandsaw, Sander, Filament Winder, Drill Press, Shop-Vac, Hand tools ● RockSAT-X: Drill press ● MSAT: Jig saw, drill press, belt sander, x winder ● NASA SLI: All of them in there currently. ● Mars Madness: Band Saw, drill ● 3DPAC: Drill Press, Tape Measure, Plyers ● Wind Turbine Team at VT: Drill press, band saw, sanding machine

12. What other machines/equipment do you need to use that aren’t available now? (e.g pneumatic lines (air))

● OLVT: 3D printer, Mitre Saw, ventilation, laser cutter, CNC, Lathe ● Rocketry at VT: CNC/mill, laser cutter, lathe, water jet cutter (we usually outsource for these and it gets very expensive) ● RockSAT-X: Metal brake, CNC machine, Ultem 3D printer ● MSAT: CNC milling machine ● NASA SLI: computer controlled cutting machine. 3D Printer. ● Mars Madness: N/A ● 3DPAC: A 3D Printer, specifically a Modix Big-60 V3. Laser Cutter (minimum 30" by 20"). Waterjet ● Wind Turbine Team at VT: A CNC machine (waterjet preferably), a laser cutter, a 3D printer, a fume hood (for things like epoxy)

13. If your team would benefit from having a 3D printer in the AEDL, what are your top 3 requirements?

● OLVT: Large print volume/space, precise print output, multiple filaments; ventilation ● Rocketry at VT: Print Volume, resolution/tolerance, can it print ABS at high in-fill? (thermals/enclosure) ● RockSAT-X: Dual nozzle, ultem print capabilities ● MSAT: Resolution, different types of materials, large printing area inside printer ● NASA SLI: Heated bed and build area. FDM (no resin). Dual extruder for soluble filament. At least 300mm X 300mm x 300mm build volume. (Good brands from highest quality down are: Ultimaker, Prusa, Creality Ender series) ● Mars Madness: N/A ● 3DPAC: Large build volume, standardized filament, 0.4 mm capable nozzle ● Wind Turbine Team at VT: Yes, this would be very beneficial. We would use this for printing parts for our turbine that have geometries that would be difficult to machine. Most of our pieces are relatively small.

14. Is there a certain model/brand of 3D printer that you are interested in getting in the lab?

● OLVT: N/A ● Rocketry at VT: Dremel Digilab 3D45 or Makerbot Replicator+ ● RockSAT-X: N/A ● MSAT: N/A ● NASA SLI: A great option would be an Ultimaker but they are very expensive. A Creality Ender series printer would be best performance per dollar and the Prusa i3 is a good middle ground but not large or feature packed. ● Mars Madness: N/A ● 3DPAC: Modix Big-60 V3 ● Wind Turbine Team at VT: no preference

15. Are the number of electrical outlets sufficient for your needs? Is the location of electrical outlets sufficient for your needs? Does your team need 220V outlets?

● OLVT: 220V would be nice to have but not immediately required, we have enough outlets ● Rocketry at VT: So far yes, more outlets would always be better ● RockSAT-X: Current outlets are sufficient ● MSAT: Good number and location. 220V outlet not needed ● NASA SLI: They are adequate. ● Mars Madness: Yes ● 3DPAC: Yes ● Wind Turbine Team at VT: I think our team is good on electrical outlets, the hanging outlet is nice.

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16. Do you have to deal with any hazardous waste (e.g batteries)? If yes, how would you ideally handle hazardous waste removal?

● OLVT: No ● Rocketry at VT: Yes, ideally we would use a hazard waste collection system. We have lithium batteries, carbon fiber particulate ● RockSAT-X: Central collection point to drop off spent batteries within AEDL ● MSAT: No ● NASA SLI: Carbon dust is an issue for us. Usually no batteries. ● Mars Madness: We do not have hazardous waste ● 3DPAC: Yes (batteries), notify the Lab manages of the battery disposal

17. What kinds of scrap materials are you having to dispose of?

● OLVT: Aluminum 6061-T6 ● Rocketry at VT: Metals (Aluminum), some hardware like nuts and bolts, Misc Electronics, some layup materials. ● RockSAT-X: wood, cardboard ● MSAT: aluminum, fiberglass ● NASA SLI: Small amounts of carbon filament and wood. ● Mars Madness: Metal and wood shavings, foam , carbon fiber residue. ● 3DPAC: Foam, plastic, wood, carbon fiber, wires ● Wind Turbine Team at VT: Aluminum and steel

18. I would work more in the AEDL if...

● OLVT: The desired equipment was available, COVID restrictions were eliminated ● Rocketry at VT: AEDL was on campus, The desired equipment was available, COVID restrictions were eliminated ● RockSAT-X: AEDL was on campus, COVID restrictions were eliminated ● MSAT: AEDL was on campus, The desired equipment was available, COVID restrictions were eliminated, Increased availability of buses on weekends ● NASA SLI: The desired equipment was available, COVID restrictions were eliminated, Our team had a larger bay. ● Mars Madness: AEDL was on campus ● 3DPAC: The desired equipment was available, COVID restrictions were eliminated, Modix Big-60 V3 ● Wind Turbine Team at VT: The desired equipment was available

19. How many of your students live on campus? (number of students/ estimated percentage)

● OLVT: probably 1/4 of the team so ~25 people; ~20 ● Rocketry at VT: ~20 students, 40% ● RockSAT-X: ~20% ● MSAT: <20% ● NASA SLI: 60% ● Mars Madness: 10% ● 3DPAC: 0% ● Wind Turbine Team at VT: 10%

20. What is the form of transportation that your team members use to get to the lab? (i.e. what percentage of students drive vs. ride the bus)

● OLVT: Car/Bus ● Rocketry at VT: Probably 100% Drive. I haven't heard of a student using the bus yet. ● RockSAT-X: ~80% drive, ~20% bus ● MSAT: Car: 80% ; Bus: 20% ● NASA SLI: 60% drive or ride from other members 40% bus ● Mars Madness: Bus - 60%, Car - 40% ● 3DPAC: 100% Drive ● Wind Turbine Team at VT: I would say 15% of students take the bus, the rest drive to the lab

21. Any other issues, comments or concerns?

● OLVT: We would like to display our rockets by hanging them from the ceiling if possible ● Rocketry at VT: The lab has practically no ventilation system. This would be a must have. Also, it would be great if the ability to weld at the AEDL was supported. We would definitely incorporate this into our manufacturing processes. ● RockSAT-X: N/A

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Appendix C – Equipment Cost Estimates

Table C1 - Low Cost Options

Item Specifications Cost Image

CNC Waterjet - Wazer Desktop Dimensions: 34” x $7900 25” x 21” (L x W x H),

Desktop Weight: 110 lbs

Processing area: Laser cutter - YH9060 900mm*600mm (3feet*2feet) $4680 Laser power: 100W Laser type: Sealed Co2 glass laser tube

Printing size: 300mm x 3D-printer FDM - IUSE I- 300mm x 300mm $1,900 300 Printer size: 500(W) x 503(L) x 660(H) mm/19.69(W) x 19.80(L) x 25.98(H) inches Printer accuracy: 0.06-0.2mm

Bar Capacity: 1.625" CNC Lathe - OKUMA Chuck Size: 6" $26,200 ESL6 CNC Lathe Spindle Speed: 6000 RPM Weight: 6170 LBS X Axis Travel: 6.1" Z Axis Travel: 12.6" Dimensions: 75" x 67" x 67"

Total: $40,800

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Table C2 - Medium Cost Options

Item Specifications Cost Image

4ft x 8ft x 1ft gantry height CNC Waterjet SIGN TEK Frame welded steel tube $28,500 4X8 CNC MACHINE X, Y axis - helical rack/pinion, Z axis - stainless ball screw

55.1 x 35.4in. (1400 x 900mm) Laser cutter- Boss Laser Cutting Area $17,000 BOSS LS-3655 81.5"L x 58.2"W x 44.5"H Machine Dimensions 1500 Watts/13 Amps Gross Power Power supply: 110 V

Large Format 3D Printer: up to 3D-printer - RAISE3D 12×12×11.8 inch | 305×305×300 $4,000 PRO2 mm High Resolution: 0.01mm layer thickness Build Plate System: Excellent warping prevention / Even heat distribution / Longer lifetime / Easy to remove

Spindle Speed: 4,000 RPM CNC Lathe - DMG MORI Spindle Motor: 25 HP $47,500 SEIKI CTX450 CNC X Axis Travel: 10.5" Z Axis Travel: 23.62" Lathe Model CTX450 Dimensions: 121" x 88" x 84" Siemens 840D CNC Control

Total: $97,000

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Table C3 - High Cost Options

Item Specifications Cost Image

Print Volume: 78” x 157” CNC Waterjet - Maximum Loading $56,900 Watertech Cutting Capacity: 662 lb/m^2 304 stainless steel cover, WaterJet Cutting cast iron frame Machine with 78" x

118" Water Tank

Cutting Area: 33.4" x Laser cutter - Boss 54.33" (850 x 1380mm) $27,000 Laser BOSS HP-3655 Laser Power: 150 Watts CO2 Machine Dimensions: 81.5"L x 58.2"W x 44.5"H Power Supply: Premium AC 110 V

3D-printer - Modix 23 x 23 x 25” in print $7,900 BIG-60 V3 Product No. volume Resolution (XYZ): 4 X 4 X MUACLF7P 0.5 micron Machine size: (WxDxH) with enclosure 906x1060x1,356 mm / 35.6 x 41.7 X 53.4 inch

Bar Capacity: 2.6" Lathe -DOOSAN Chuck Size: 8" $69,900 LYNX 2100LB CNC Spindle Speed: 4,500 RPM Spindle Motor: 20 HP Lathe Model LYNX X Axis Travel: 8.1" 2100LB Z Axis Travel: 22" Dimensions: 102 x 63 x 66 Weight: 7,500 LBS

Total: $161,700

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