Undergraduate Research Opportunity Program – UIUC Students Only

Project #1  – Agricultural Drone Design Methodology Development for Senior Capstone Course

Mentor: Dr. Elle Wroblewski

Building from preliminary research by AE 298 RES students in Spring 2025 and further developing the following research tasks:

• Researching how to design agricultural drones for different purposes related to sustainable agriculture or permaculture practices.
• Researching how to fabricate drone components from recycled post-consumer waste.
• Researching the costs and feasibility of constructing these types of drones by senior undergraduate students in a capstone course.
• Researching the technical information and education required for senior undergraduate students to complete the project.

Student Activities

• Reading
• Critical Thinking
• Fabrication Experience
• Independence
• Time Management
• Understanding of Agriculture
• Understanding of Sustainability
• Understanding of Undergraduate Student Education
• Understanding of Aviation & Drones

Number of positions available: 1

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Project #2 – Assessment of spatial visualization training effectiveness for undergraduate students

Mentor – Dr. Brian Woodard

Decades of research involving many thousands of participants has consistently shown that spatial skills are one of the strongest predictors of future success in STEM coursework and STEM careers independent of math and verbal ability. Research also shows that spatial skills are malleable, and individuals may need different methods to practice and improve their skills. For example, a series of studies showed that gender differences in STEM education could be reduced by enhancing spatial skills through computerized training that involves different forms of practice in solving spatial visualization problems.

Based on this background information, The Grainger College of Engineering has been offering an elective spatial visualization training course for first-year students since 2019 (ENG 177 Spatial Visualization). Data have been collected regarding these students’ spatial visualization abilities before and immediately after the course. Additionally, a large dataset is available showing the longitudinal impact of the training course on these students’ success in their subsequent STEM courses. Data organization, analysis, and visualizations are needed to investigate and publicize these outcomes illustrating the impact of this particular course and the importance of spatial visualization skills more generally in STEM.

If certain types of visualization exercises are found to be particularly beneficial, the student may also develop new instructional materials to support the visualization course.

A successful student for this project will have an interest in Engineering Education research. Skills with programming for organizing datasets and creating visualizations are required. Statistical analysis will be needed to examine the data, so some background knowledge in statistics, or willingness to learn some statistical analysis, is required. Experience with CAD (preferably NX), a rendering program like Blender, and 3D printing will also be beneficial if new instructional materials are developed.

Number of positions available: 1

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Project #3 – Development of a Hardware-In-The-Loop Test System for the IlliniSat CubeSat Bus

Mentor(s): Dr. Victoria Coverstone and James Helmich (Grad Student)

The IlliniSat CubeSat Bus is a modular system with the objective of reducing the assembly integration and testing (AIT) process for small payloads with a novel “plug and play” approach. The major subsystems are compartmentalized in this architecture to parallelize the critical paths of avionics and payload development. The overall system is broken down into smaller components which make anomaly identification and troubleshooting more manageable. The design is a 6U satellite with 2U (10 x 10 x 20 cm) of space for payload volume and two 2U modules dedicated to power, attitude determination and control, command and data handling, and communications subsystems.

The IlliniSat program has recently completed its Preliminary Design Review (PDR) and is working towards a Critical Design Review (CDR). This project is part of the larger IlliniSat program to realize the novel design and fly a CubeSat utilizing the IlliniSat Bus. This project focuses on the development of a Hardware-In-The-Loop Test System (FlatSat) representation of IlliniSat’s components and subsystems. This development involves utilizing a preassembled FlatSat development board, and writing software to simulate sensor readings, implement control algorithms, develop a command and data handling environment, and perform real-time simulations.

We are looking for enthusiastic undergraduate students with systems, aerospace, electrical, or computer engineering backgrounds interested in both research and hardware development. Research interests should align with the space systems field. Previous design experience working on hardware and electronics intended for use in space environments is a plus but not a requirement. Previous coding experience is necessary, particularly in C and Python. Additionally, availability to continue work into the next academic year is a plus but optional.

Students involved will have the opportunity to work with a group of engineers in the laboratory environment and use simulation and modeling software for structural, orbital dynamics, and concept of operations analysis. Students will learn to operate test equipment necessary to conduct research operations.

Students will be involved in:

• Developing simulated sensor output generators.
• Implementation of control algorithms for multiple forms of in-flight control hardware.
• Developing a command and data handling environment.
• Conduct real-time simulations of the satellite while in orbit.
• Time permitting other activities (such as link analysis).

Number of positions available: 1

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Project #4 – Formulation of System Definition for a Dual-Mode Propulsion, Monopropellant-based, CubeSat

Mentors: Dr. Victoria Coverstone, Dr. Joshua Rovey, Prof. Matt Hausman, and Michael Harrigan

Multi-mode propulsion enables significant flexibility and adaptability of the spacecraft. Recent efforts have focused on developing compact chemical and electric multi-mode propulsion solutions to address modern missions’ immediate/high thrust and high efficiency/low thrust needs. Typically, two independent systems would be designed for each of these thrust-generating capabilities, but by utilizing a monopropellant, a single propellant tank and feed system can be used for both types of thrust. This capability has been demonstrated in the lab environment but has yet to be implemented on an in-situ satellite.

This project is part of a more extensive program to realize this architecture and fly a CubeSat utilizing a monopropellant and multimode propulsion system. This project focuses on the early system definition phase of the program on the satellite bus side of development. During this phase, the requirement generation process takes place, trade studies are conducted, and systems are identified for use in future analysis and the hardware development stages.

We are looking for enthusiastic undergraduate students with systems, aerospace, electrical, or computer engineering backgrounds interested in both research and hardware development. Research interests should align with the space systems field. Previous design experience working on hardware and electronics intended for use in space environments is a plus but not a requirement. Additionally, availability to continue work into the next academic year is a plus but optional.

Students involved will have the opportunity to work with a group of engineers in the laboratory environment and use simulation and modeling software for structural, orbital dynamics, and concept of operations analysis. Students will learn to operate test equipment necessary to conduct research operations.

Students will be involved in:

• Reviewing and refining current system requirements.
• Conduct trade studies on state-of-the-art versus traditional technologies.
• Develop new tools and methods that can be utilized for system/subsystem/component level evaluation.
• Review, refine, and track resource budgets within the current system design (e.g., Mass, Volume, Power, Data, Comms).
• Risk Identification
• Failure Mode and Effects, Lifetime Cost, Safety Concerns, and Risk Analysis.

Number of positions available: 2

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Project #5 – Human-Centered Aerospace Engineering Design in a Supplementary Self-Study Canvas Course

Mentor: Dr. Elle Wroblewski

Building from preliminary research by AE 298 RES students in Spring 2025 and further developing the following research tasks:

• Researching how to incorporate human-centered design in aerospace engineering vehicle design and experiment design.
• Researching how to human-centered design can be used to teach engineering.
• Researching what must be included in an optional, supplemental, no-credit self-study course for students to be successful in engineering.
• Research how to use human-centered design in engineering craft projects to build technical skills and create experiences for design thinking to be utilized.
• Researching what is required for a self-study course to allow students to learn at their own pace.
• Research what type of assessments or discussion forums a self-study course should have to allow for social learning and project feedback.

Student activities:

• Reading
• Critical Thinking
• Teaching Experience
• Independence
• Time Management
• Understanding of Teaching & Learning Practices
• Understanding of Aerospace Engineering Design
• Understanding of Undergraduate Student Education
• Understanding of Psychology and Human Cognition

Number of positions available: 1

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Project #6 – Improving Damage Resilience and Detection for Carbon Fiber Composites

Mentors: Dr. Jeff Baur & Ivan Wu

This project focuses on improving the impact resilience of carbon fiber composites and developing thermography-based machine-learning approaches for sensing post-impact damages. Through tuning interlaminar fracture toughness and fiber angles, we hope to improve impact resilience and tolerance of poly-dicyclopentadiene (pDCPD) based composites compared to traditional aerospace grade epoxy. Post-impact samples will be placed under a vacuum chamber for in-situ thermography and compared to true damage from X-ray computed tomography (CT). These results will then be used to calibrate a heat-transfer-based numerical model and to provide training data for neural network algorithms in order to significantly improve the time and accuracy of machine-learning approaches in sensing composite damages.

Student Activities – The student will spend half of the time manufacturing composites and completing low-velocity impact tests on such samples while utilizing the other half of the time generating and analyzing thermography and X-Ray CT data. As such, it is recommended that the student is comfortable with handling chemicals and operating mechanical testing/optical equipment. Moreover, they should be familiar in analyzing datasets with Python as the thermographic images are output as three-dimensional arrays that need to be post-processed with Python scripting. Finally, any previous experience with composite manufacturing is preferred.

Number of positions available: 1

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Project #7 – Processing for In-space Manufacturing of Composite Structures

Mentors: Dr. Jeff Baur, Zheyuan Zheng (2nd year PhD), Ivan Wu (3rd year PhD)

This project investigates concepts for space-based manufacturing of high-performance composite structures. The research uses Ring-Opening Metathesis Polymerization (ROMP) of dicyclopentadiene (DCPD) to develop an automated system for fabricating lightweight, high-strength composite tubes with minimal energy consumption. This fabricator incrementally cures and extrudes composite tubes from compact, stowable raw materials. The experiment involves control over the polymer reaction condition, including the precise and time-sensitive application of heat, pressure, and cooling.  Rigorous testing on both the system and manufactured tubes is required to ensure successful operation in a space environment.

The student(s) will spend the first part of their time working on assembly and initial testing of the fabricator and development of the processing procedure. Flight hardware will be assembled in a clean room. For the second portion of their effort, the student will use the fabricator to make composite tubes and characterize their properties. The student(s) working primarily on fabrication assembly should be comfortable handling, assembling, and using mechanical hardware in a controlled environment. Previous experience working in a cleanroom, handling of spacecraft, operating a TVAC chamber/shaking bed or any spacecraft testing experience is preferred. Student(s) working primarily on processing should understand the effect of heat and pressure during polymer curing. Previous experience with polymer or composite processing and a strong materials or chemical background is preferred.

Number of positions available: 2

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Project #8 – Processing- Structure Relationships of Additively Manufactured High-Temperature Vascular Composites

Mentors: Dr. Jeff Baur (PI), Atik Rahman (Post-Doc), Asim Shahzad and Han Lee

a.  This project has several aspects in the additive manufacturing of pre-ceramic composites, processing them into a high temperature composite, and characterization of the internal structures that results from that processing. We will match applicant desire and capabilities to the following project sub-elements (1) Vary the pyrolysis heating and cooling profiles to understand the resulting porous networks. If time allows and the process is developed, ultra-high temperature particles are to be involved. This includes mixing and dispersing of the particles, printing and infiltrating with the particles, then varying the same goal of investigating the porous structure as above.

b.  (2) Analyze the porous structure of the additively manufactured composite throughout each Polymer Infiltration and Pyrolysis (PIP) cycle to analyze how the porosity evolves over the cycles, then to correlate its structure to permeability capabilities (Figure 3).

The undergraduate research assistant will learn with the graduate student mentor the process development to achieve an additively manufactured composite (Figure 2). The student shall learn how to operate various equipment to be able to manufacture the composites and to analyze them, including CF3D (Figure 1), ovens, furnaces, infiltration setups, X-ray CT characterization software, and some python programming. From the analysis that the undergraduates provide, we plan to relate them to the permeability capabilities that will dictate the infiltration and thereby the densification, as well as its future application for transpiration cooling.

Number of positions available: 2

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Project #9 – Process-Structure-Property Relationships of Continuous Fiber-Additive Manufacturing

Mentor – Dr. Jeff Baur (PI), Thien Le (MS ’26)

The objective of this project is to develop methods to rapidly investigate the processing-structure-property relationships of in-situ impregnated continuous fiber additively manufactured composites with novel reactive polymer resins.

Additive manufacturing with continuous fiber composites is a rapidly developing field that is more automated, provides tailored properties at the tow level, and can create complex geometries compared to traditional composite manufacturing techniques. Continuous Composites Inc.’s CF3D machine is one such system that additively manufactures continuous fiber composites as shown in Fig. 1. However, this system currently has a very limited library of certified materials, thereby limiting the output of unique, multifunctional material systems.

In this project, a multi-functional, hybrid composite system of continuous carbon fibers, nanofillers, and novel polymers like UV-curable and frontally polymerizing resins will be studied. These materials are chosen because 1) continuous carbon fibers impart superior mechanical properties compared to AM materials, 2) nanofillers impart multifunctional (thermal, electrical, sensing, etc.) properties, and 3) novel polymers enable rapid and low energy curing in comparison to traditional thermosets.

We will define and characterize the processing window using our custom built “Test Bed” apparatus shown in Fig 2. This apparatus is developed to mimic many key features of the CF3D system such as fiber compaction, resin impregnation, UV curing, and fiber placement while also having many more expanded features such as a heated substrate, a cooling system, variable tow angle, and custom impregnation algorithms. The Test Bed will serve as a sandbox to safely and inexpensively experiment with new material systems to understand the mechanics of composite additive manufacturing without the risk of damaging expensive systems such as CF3D with experimental materials.

For this study, the thermomechanical properties, microstructure, and curing kinetics will be characterized as a function of resin viscosity, nanofiller composition, and single-tow compaction force.

From a technical standpoint, the undergraduate research assistant will assist the graduate student mentor in planning, conducting, and characterizing the experiment. This will include (1) using CAD and 3D printing to design and manufacture processing fixtures, (2) being very hands-on in the lab and developing creative solutions on the fly, and (3) being able to interpret data, relating it to process-structure-property relationships for AM composite materials to inform the most productive experimental path forward. The research assistant will learn industry-standard composite material analysis methods such as optical microscopy, differential scanning calorimetry (DSC), and dynamic mechanical analysis (DMA). The research assistant will also learn composite manufacturing fundamentals such as material preparation, microstructural properties, and optimal processing conditions.

From a non-technical standpoint, the undergraduate research assistant will be given the opportunity to lead aspects of this project under our mentorship. The research assistant will also learn effective communication and time management skills. They will also be required to present their findings in the form of a presentation and a paper.

Student Prerequisites

An important prerequisite is to be curious and ready to learn! Most of the required skills will be taught in lab, so being able to ask questions and being hungry for knowledge is key!

Some desired qualifications include: 

• Having taken at least one structures/materials course including but not limited to Engineering Materials, Solid Mechanics, Applied Aerospace Structures, Mechanics of Composites, Polymer Science, etc.
• Prior experience in composite manufacturing or material analysis
• Prior experience working in a laboratory setting
• Prior experience in working within a technical team including student organizations such as rocketry team, FSAE, etc.
• Prior experience in mechanical or electrical design

Number of positions available: 2