Date of Award

5-5-2025

Degree Type

Capstone Project

First Advisor

Bahram Nassersharif

Abstract

This project, sponsored by Mearthane Products Corporation (MPC), focused on improving the labor-intensive and environmentally harmful process currently used to clean and finish high-performance roller skate wheels. MPC’s existing workflow relied heavily on manual labor and the use of solvents like WD-40 and Scotch Brite pads to remove silicone mold release agents and prepare the wheels for UV ink printing. The main objectives of the project were to enhance operator safety and ergonomics, eliminate hazardous and excessive chemical use, increase throughput, and maintain or improve wheel quality as measured by scratch and tape tests.

To achieve these objectives, Team 15 developed a two-step cleaning and abrasion system consisting of an industrial dishwasher and a custom-designed ergonomic abrasion rail system. The dishwasher was chosen to eliminate the use of solvents and to automate the initial cleaning phase. Extensive validation, including over 150 wheel tests, demonstrated that the dishwasher could reliably remove surface contaminants. However, to ensure the wheels passed all quality control metrics, an additional abrasion step was required. This led to the design and fabrication of the abrasion rail system, which allows operators to scuff the wheel surface while minimizing strain on their fingers and reducing fatigue.

Key design specifications included a 3' x 3' footprint to fit the existing manufacturing space, a throughput rate of 350 wheels per hour, ergonomic considerations to relieve operator fatigue, and a project budget cap of $50,000. The final solution met all these requirements. The rail system, in particular, enables the operator to retain control over the abrasion process while significantly improving working conditions. The modular design of the rail system allows for flexible scaling; additional operator stations can be added as needed to match dishwasher output and accommodate varying production demands.

The project yielded several noteworthy accomplishments: the successful integration of an industrial dishwasher into MPC's workflow, the elimination of solvent-based cleaning, improved ergonomics through mechanical aids, and a scalable, modular system ready for further automation. The new process not only meets but exceeds the quality standards for wheel surface preparation, as confirmed by consistent passing results in scratch and tape tests.

Looking ahead, there is potential to further enhance the system by motorizing the abrasion mechanism, which would reduce operator involvement and further streamline the process. The modularity of the current design provides a solid foundation for this future automation. Through this project, MPC is now positioned to improve worker safety, reduce environmental impact, and increase production efficiency without compromising product quality.

This work represents a successful application of engineering principles to a real-world manufacturing problem, demonstrating both practical impact and the potential for continued innovation.

Comments

Team Name: Team 15

Company Sponsor: Mearthane Products Corporation (MPC)

Sponsor Representative: James Boyce

Document Reference: URI-MCE-402-015-2025

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