Embedded Files
Electrospinning Mechanism
Objectives
Objectives
To modernize a legacy electrospinning device that originally supported only flat plate collection by integrating a touchscreen-based control system, designing a modular spinning disc collector, upgrading the motors and structural components, and improving usability and reliability. The redesigned system supports both plate and disc collectors through a GUI, enabling real-time parameter adjustment and motor control for rapid tuning, reduced setup time, and flexible fiber deposition testing. This project was completed in MAE 4287: Design Project I at UT Arlington.
Quick Summary
Quick Summary
Project Type: Capstone Team Project (4 members)
Team Members: Stephanie Zuniga, Thien Chau, Christen Smith
Duration: 5 months
Tools Used: SolidWorks (CAD & simulation), GUIslice (touchscreen UI), Arduino (embedded control), manual stress and torque calculations
Legacy System:
Fixed flat plate only
Hardcoded motion logic
Structurally weak PLA column prone to buckling
Key Upgrades:
Integrated interchangeable spinning disc collector
Replaced legacy code with touchscreen-based GUI (RA8875 display)
Upgraded motors and implemented belt-pulley transmission
Redesigned vertical column using aluminum extrusion for stability
Outcome: A modular collector system with a touchscreen GUI, structurally reinforced hardware, and verified safety factors for continuous electrospinning operation.
Technical Details & Skills
Technical Details & Skills
Designed and implemented tabbed touchscreen GUI in GUIslice for RA8875 + Arduino Mega
Programmed embedded motor control callbacks for indexing, rotation speed, and Z-height positioning
Modeled torque transfer and calculated safety factors for belt-pulley system (shaft, key, bearing)
Performed manual stress, shear, and bearing analysis for keyed disc-shaft connection
Contributed to hardware design for improved column rigidity and modular collector interchangeability
Optimized GUI asset storage using PROGMEM to overcome Arduino Mega memory constraints
Design Overview & Features
Design Overview & Features
Enclosure
Touchscreen Interface
7.0” resistive display with three tabbed modes:
Home: Mode selection (PLATE or DISC)
Plate: Rail speed and Linear indexing control
Disc: Rail speed and Rotation
Color-coded buttons for improved usability and error prevention during lab operation
Collectors
Flat Plate: Legacy design retained for compatibility
Rotating Disc: Modular subassembly with keyed aluminum disc for rotational collection
Motors
Anaheim Automation 17MD302S-00 stepper motors with integrated drivers (no external controller required)
Drive System
Belt-pulley transmission with verified tension and bearing safety margins
Structure
Column: Replaced legacy 3D-printed column with aluminum extrusion and L-bracket base to prevent buckling
Base Plate: Modular design accommodates both plate and disc collectors
Enclosure: PMMA housing minimizes airflow disturbances and improves fiber deposition consistency
Touchscreen Design Evolution
Touchscreen Design Evolution
Initial Touchscreen Interface Design
Updated Touchscreen Interface Design
Final Touchscreen Interface Plate Tab
*Note: Interface created in GUIslice Builder and integrated with Arduino Mega motor control via callback functions and tabbed layout.*
Video Documentation
Video Documentation
A short demo video showcases touchscreen-based control of the X-axis motor speed using the GUI’s interactive spinners. The touchscreen sends real-time speed commands to the motor, demonstrating accurate user input response and successful interface-to-hardware integration.
Simulation & Engineering Decision
Simulation & Engineering Decision
Manual calculations: torque, pulley ratio, and belt tension validation
Required Torque: Calculated ~21.1 oz-in to spin the 8” aluminum disc
Pulley Ratio: Selected 1.64:1 to balance motor RPM and disc speed
Belt Tension: Determined using Euler’s belt equation (~36.7 N)
Shaft Design Validation:
Shear stress safety factor: SF > 1000
Bearing stress safety factor: SF = 14.6
Designed for long-duration electrospinning operation with conservative >10× safety margins for mechanical components
Hardware Overview & Team CAD
Hardware Overview & Team CAD
Belt-pulley system
Rotating disc collector with belt-pulley transmission, shaft, and integrated motor (17MD302S-00)
Shaft with machined keyway
Legacy PLA 3D print column design
Column evolution: Redesigned with aluminum extrusion + base brackets to resist buckling and ensure stability during long operation.
*CAD models shown were created by team members for fabrication, assembly visualization, and documentation.*
Challenges & Iteration
Challenges & Iteration
Replaced buckling-prone 3D-printed column with aluminum extrusion for improved rigidity
Redesigned disc–shaft connection to prevent detachment under belt tension
Integrated legacy motor logic into new touchscreen interface with safety-first callbacks
GUI evolved through multiple iterations based on client and advisor feedback
Memory constraints on Arduino Mega exceeded capacity; resolved by moving text/images to PROGMEM
Unified PLATE and DISC control into shared tabbed GUI with modular logic routing
Outcomes & Contributions
Outcomes & Contributions
Designed and implemented the touchscreen GUI with full motor control logic and real-time callbacks
Performed mechanical analysis for belt tension, bearing loads, and shaft stresses
Led torque calculations and verified safety margins for the rotating disc drive system
Skills Applied
Skills Applied
Touchscreen Programming · GUIslice Builder · Embedded Arduino Control · Motor Indexing Logic · Belt-Pulley Torque Analysis · Shaft Stress & Bearing Calculations · Technical Communication · Engineering Presentation · SolidWorks Documentation
Reflection
Reflection
This capstone project taught me how to integrate mechanical and electrical subsystems into a modular, research-grade device. Developing and coding the touchscreen interface helped me bridge embedded programming with real-world motor control. Through belt-pulley analysis and shaft loading calculations, I gained confidence in applying torque models and evaluating mechanical safety margins.
Presenting this project strengthened my ability to step beyond my assigned section, engage with clients, and collaborate across disciplines. Working alongside teammates from diverse technical backgrounds taught me how to translate mechanical specifications into robust control logic. Overall, the project sharpened my cross-disciplinary problem-solving skills and deepened my interest in mechatronics, embedded systems, and user-centered hardware design.
*Note: As this project was part of a capstone and intended research application, the full report, CAD files, and source code are not available for public distribution*
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