Capstone Design Expo 2025

Michael Benedetto, Chisom Okoro, and Brandon Ruiz

Dr. Nagasree Garapati, PE

Max Fernandez, Associate Process Engineer, FuelCell Energy Inc.

FuelCell Energy Inc., a leading innovator in high-efficiency combined heat and power

To design and develop an advanced exhaust heat recovery heat exchanger for molten-carbonate fuel cell systems with the goal of achieving system efficiencies exceeding 90% through innovative methodologies. The project also investigates the capture and treatment of condensed water from exhaust gases as a sustainable, reusable resource for fuel cell reactions. This design seeks to enhance overall system performance, promote circular water utilization within the fuel cell process, and align with clean energy and environmental sustainability goals.

Daniel Cerulli, Kian Fatemi, Nicholas Larkin, Lucero Melendez, Joshua Stewart, Declan Straut, and Johnell Taylor

Dr. Mehdi Mekni

To develop a virtual reality (VR) networking education tool that overcomes the limitations of restricted access to modern, expensive networking equipment in academic settings. The tool leverages VR’s proven ability to enhance engagement and knowledge retention. The project bridges the gap between outdated academic resources and current industry technologies. The platform will provide a validated, cost-effective alternative to traditional physical labs, ensuring pedagogical accuracy while promoting collaborative, hands-on skill development in networking technologies.

Mateusz Wiszniewski, Justin Vasquez, Maddie Backus, Andrew Haller, and Johnathan George

Dr. Mehdi Mekni

To enhance the dining experience at the University of New Haven through the development of Nutritional Overview Manager — a UI/UX-optimized platform designed to address key shortcomings in the current system, including inaccurate information, limited accessibility, and inefficient menu updates. The platform prioritizes data integrity, secure user interactions, and traceability to provide a user-centric application that empowers students to make informed dining choices while streamlining dining operations.

Ryan Stapleton, Ronald Scarpa, Chistopher Protheroe, and Nick Delagrotte

Dr. Tirthankar Ghosh

To develop a code obfuscation tool integrated with artificial intelligence features. The tool will allow users to upload their code, which will then be automatically obfuscated and returned. This solution will benefit programmers and developers by eliminating the need to manually create complex code for obfuscation, saving time and effort while enhancing code security.

 

 

 

 

Alexandra Iozzo, Benjamin George, and Matthew Gomerez

Dr. Ismail Orabi

Matthew Lang, Senior Automation Engineer, and Marc D’Urbano, Engineering Manager — Mechanical, Edgewell

Edgewell Personal Care, a trailblazing personal care company that leverages its employees’ creativity and passion to challenge convention and drive growth

To enhance and optimize Edgewell’s current blade strip welding and dressing processes. The team will conduct research and design, test, and propose solutions to streamline these processes. The anticipated outcome is a reduction in production time and an increase in overall efficiency for Edgewell.

Justin Ortiz and Michael Coppola

Dr. Ismail Orabi

Derek Favret, Manufacturing Engineering Supervisor, RBC Bearings

RBC Bearings, designer and manufacturer of highly engineered precision bearing components and essential systems for the industrial, aerospace and defense industries

To reduce Heim Bearing’s design time and costs by validating and improving their swaged bearing design model through both physical and analytical testing. The properties of the maintenance-free liner will be evaluated through physical compression testing, and the results will be incorporated into the Ansys FEA model, replacing the current generic linear isotropic properties. Ansys Response Surface Optimization will be utilized to generate new preprocess component geometry and tooling specifications. If time permits and validations are successful, work instructions will be developed for the Heim engineering team to ensure consistent creation of tooling and component preprocessing sizes using the enhanced FEA optimization software.

Semih Akyuz, Angela Mercaldi, and Tyler Pendleton

Dr. Ismail Orabi

William Welsh, Sr., Technical Fellow, Sikorsky, Lockheed Martin

Sikorsky, a Lockheed Martin Company — A global leader in supporting customers’ missions, strengthening security and advancing scientific discovery

To test and enhance the design of a new fast active vibration compensation system. Replace previous variants with a more efficient system that reduces latency, weight, and footprint by utilizing an innovative power delivery method. The system is crucial for improving component longevity and ensuring crew comfort, particularly during high-stress situations and tight maneuvers. Validate the feasibility of an existing proof-of-concept prototype developed at the University of New Haven. Subsequently, further optimize the system’s weight, footprint, durability, and manufacturability.

Ashton Brunell, Phelopateer Ibrahim, and Benjamin Norodom

Dr. Joseph A. Levert, PE

Richard Cerniglia, Engineering Supervisor, Fluid Systems, General Dynamics Electric Boat

General Dynamics Electric Boat — 125 years of established standards of excellence in the design, construction, and life cycle support of submarines for the U.S. Navy

To develop a relief valve for a specialized application that significantly minimizes vibration during seating (closing) while extending service life. The project will enhance an existing commercially available valve design by optimizing the seating mechanism to reduce undesirable vibrations and improve the durability of the poppet and seat, achieving a target of 35,000 open/close cycles. This advanced valve design aims to enhance overall ship system performance and reliability while also reducing the maintenance costs associated with the short service life of current valve models.

Shaunessy Reynolds, Erik Parker, Aidan Stoner, Erin Mae Cardino, and Marc Santacapita (Electrical and Computer Engineering); Joseph Marcello and Aidan Stehlik (Mechanical Engineering)

Drs. Shayok Mukhopadhyay and Joseph A. Levert, PE

The Mars Society, University Rover Challenge

Individuals: Anil Shah, Robert Alvine, Mike Ambrose, and Bill Welsh

Companies: Protospace MFG, BTX Global Logistics, ODrive, and Rokland

To build a rover to compete in the University Rover Challenge, an annual international competition in which university students design and build Mars rovers to complete tasks across four key missions: equipment servicing, autonomous navigation, science, and extreme delivery. The rover will be equipped with an arm, chassis, drivetrain, power distribution unit, sample collection system, and autonomous navigation system. It will weigh under 50 kg, fit within a 1.2 × 1.2 × 1.2-meter cube, and have a total cost not exceeding $22,000 including all expenses.

Julia Casella (Engineering), Carlos Chaparro (Mechanical Engineering), Logeswaran Kattikulam Ganesan (Electrical and Computer Engineering), and Gabriel Olszewski and Bryce Titus (Computer Engineering)

Dr. Mohsen Sarraf

Shanthala Nagesh, Honeywell

Honeywell, a global leader in technology and manufacturing, delivering innovative solutions in aerospace, building technologies, fire alarms, performance materials, and safety to enhance efficiency, sustainability, and performance for customers worldwide

To convert an existing Arduino-based standby operating test fixture to a Beckhoff PLC system. The fixture, designed in accordance with UL 864 (10th ed.) and ULC S527 (4th ed.), is used for testing charging current and standby operating power for releasing devices. By adjusting dwell and transfer times, the updated fixture will be capable of complying with multiple fire and security charger test standards. The system will control a fire alarm control panel or power supply unit to operate in Normal Standby, Alarm, and Releasing modes using the Beckhoff PLC. This will involve programming various relays to simulate panel conditions, control loads, send scan signals to a Keysight data acquisition meter, and provide multiple positive feedback signals from the panel.

Anthony Mauro and Nikolas Troast (Electrical Engineering); Morgan Fabbricatore and Raymond Pagan (Mechanical Engineering)

Dr. Joseph A. Levert, PE

Will Fergueson, Hitchner Manufacturing Co.

Hitchner Manufacturing Co., a complete-to-print castings manufacturing company specializing in components for the automotive, aerospace, and defense markets

To design and develop a device for externally monitoring the internal temperatures of a ceramic mold preheating oven, where temperatures exceed the limits of commercially available sensors. The automated system will use noncontact sensors to rapidly measure the temperature of removable ceramic mold covers as they exit the furnace onto a chute. Temperature data will be automatically transferred to the site’s digital storage system while an automated notification system will alert operators when the storage cartridge requires emptying. This solution will enhance temperature tracking accuracy, enabling scheduled maintenance to prevent costly, unplanned shutdowns.