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Ashley, Cadrex, Apogee among companies benefiting from engineering students’ prototypes

giffeyt — Mon, 15 Jun 2026 12:45:05 +0000

Ashley, Cadrex, Apogee among companies benefiting from engineering students’ prototypesgiffeyt June 15, 2026

Capstone projects demonstrate mechanical, manufacturing know-how, leadership skills

�� Polytechnic mechanical engineering student Dominick Marco faced several challenges when he became team leader for the second semester of a capstone project on behalf of Cadrex Manufacturing Solutions.

In addition to designing and building a prototype that would automatically assemble a plastic latch and a steel bracket into a completed part, Marco had to ensure that his six-member team stayed on track as the project deadline – and graduation – approached.

Marco wasn’t just learning engineering; he was learning leadership.

“I worked on delegating by asking questions rather than directing, and through this and similar techniques, I was able to stay up to date on my team ��. progress while helping direct team members to work on important tasks without overstepping or feeling like I was micromanaging,” explained Marco, of Eleva.

“Working on a project like this with a team is a very valuable experience,” Marco continued. “Learning alongside other up-and-coming engineers has been an incredible two semesters.”

Students, faculty and industry representatives examine the prototype for Cadrex after the demonstration.

Such applied learning, which is key to the polytechnic mission that distinguishes �� Polytechnic, was on display in mid-May as mechanical engineering and manufacturing engineering seniors presented their capstone projects to industry leaders, faculty members and peers. These two-semester projects aren’t theoretical exercises. They lead to real, working prototypes designed to solve problems for industrial sponsors. In addition to Cadrex, one of the nation ��. largest metal fabricating firms, corporate sponsors included Ashley Furniture, Tomahawk Manufacturing, Apogee Enterprises, Genesis Industries, Frost Inc. and Industrial Heat Transfer.

“This course sequence truly is a capstone on a student ��. academic career at �� Polytechnic,” said Assistant Professor Nathan Spike, part of the capstone teaching team. “Over the two semesters, a student completes the transition from engineering student to a full-fledged, career-ready manufacturing or mechanical engineer – or, in some cases, both for students pursuing a dual major. Students can put what they have learned in these courses directly into practice as they transition into their engineering career.”

According to the university ��. most recent First Destination Report, 100% of 2024-25 graduates from the manufacturing engineering program reported they were either employed or continuing their education within six months of graduation, with an average starting salary was $76,000. During the same period, mechanical engineering graduates had a 99% employment rate within six months and an average starting salary of $66,000.

A �� Polytechnic student adjusts piston positions in the prototype. / Submitted photo

Process teaches communication skills

At the culmination of the capstone process, second-semester teams offer presentations of their mechanical and manufacturing solutions, then demonstrate them. During their presentation, Marco and his team – fellow seniors Aiden Koepsel, Ben Swift, Will Schlafke, Darren Byle and Josiah Castleberg – described their project scope and how they reached their final design. Originally, they considered a conveyor belt to carry the two parts. However, this was ultimately replaced with static, angled ramps that bring the two pieces together to become the completed part, which ultimately will be used in a battery holder in a data rack enclosure.

Later, the Cadrex group and other capstone teams moved into a nearby lab in Fryklund Hall to demonstrate their projects. The Cadrex prototype, a single workstation on casters, came to life, smoothly combining the pieces into completed latches, which flowed into a plastic bin.

The prototype that students developed for Cadrex Manufacturing Solutions combined these two pieces into one component.

After the demonstration, team members chatted about the prototype with Wayne Greensky, an automation engineer at Cadrex ��. Osceola plant, who provided technical input during the project. While the students had solid technical understanding when they began the project, what really grew over the course of two semesters was their communication skills, Greensky said.

“Communication with project stakeholders helps students shake off communication anxiety and prepares them for proper meeting etiquette, structure, and progress update communications, while also dealing with customer dictated deliverables,” Greensky said.

The �� Polytechnic students handled challenges – including bill of materials ordering and issues with electrical schematics – promptly and professionally, he added.

“This type of project is useful for getting engineering students comfortable with solving an unsolved problem,” Greensky explained. “Undergraduate degree curriculums typically do not prepare the students with coursework that does not have a ‘correct’ answer or solution method. This senior design experience fills that gap nicely.”

Students discuss a pallet destacker they designed on behalf of Ashley Furniture.

Efforts aimed at automation

During the spring semester, the Cadrex capstone group was just one of 13 teams composed of 83 students from �� Polytechnic ��. Robert F. Cervenka School of Engineering who worked on projects in Fryklund Hall labs.

Senior Sawyer Boigenzahn, a manufacturing engineering major from Mondovi, was the first-semester team lead for a project to create an automated system to wash and dry extruded aluminum window frames for Apogee Enterprises, owner of the Wausau Windows and Walls brand.

The frames, Boigenzahn explained, are processed in a CNC machine and emerge covered in chips, coolant and cutting fluid. Currently, the parts must be washed by hand, which leads to inconsistent cycle times. Automation would improve the quality and consistency of the process, ultimately saving Apogee time and money.

The five-member team – which also included Boigenzahn, Logan Boettcher, Brody Bongaarts, Brooks Brewer, and Joseph Gardner – conceived of a device that operated something like a car wash, but they pondered whether the sprayer or the aluminum part itself should be what moves. Ultimately, Boigenzahn explained, they decided it was easier to move the part through the sprayers than vice versa.

Based on feedback from their end-of-semester presentation, the team will return to build a prototype of their design in the fall semester. “We are at the start of that process, because this is a very difficult process to automate,” he said.

Boigenzahn, who previously worked as a welder, said the capstone project is a reminder that engineering isn’t about a single input inevitably leading to a single output: It ��. a practical discipline that involves hands-on craft.

“For us, it ��. an experiment in terms of our ability to understand the mechanical and engineering principles that we’ve been taught and actually apply them in the real world,” Boigenzahn said. “And more importantly, when you encounter real world problems – including teamwork issues, design problems, people giving you conflicting advice – how do you try to solve them? The thing about design is that you can’t just plug it into a computer and it spits out the right answer. That is just not the way this works.”

Despite the challenging work involved in the capstone process, Boigenzahn said it ��. ultimately a valuable part of the �� Polytechnic experience. “I don’t think Stout would stand out as much if we did not do these things,” he said.

Capstone students cut holes in an electrical box while building their prototype for Cadrex Manufacturing Solutions. / Submitted image

Teamwork connects students, faculty, industry partners

The capstone process is a team effort, and not just among the students: In addition to Spike, instructors include Senior Lecturer Glenn Bushedorf, Lecturer Anwr Albaghdadi, Lecturer Brandon Dick and Lecturer Niloofar Moradian, with technical support from Paul Craig, program director for manufacturing engineering.

And it ��. an effort that leads to results for industry sponsors, Spike explained. “The prototypes students develop often serve as a starting point or otherwise inform the direction a company will go with their process or product,” he said.

In addition, two semesters of intensive, iterative capstone work provide invaluable experience for emerging engineers as they enter the job market.

“Getting the chance to be a part of a project like this and create such a cool prototype machine for Cadrex has honestly been one of the best experiences to date,” Marco said. “This is the largest, most expensive project I have ever been a part of, and it makes me emotional seeing it come to a close. I am sad knowing that I will most likely never see it after it ships away, but I am so very happy to have gotten to design, develop and assemble the prototype.”

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Capstone projects demonstrate mechanical, manufacturing know-how, leadership skills

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Hired before graduation at Absolut Manufacturing

Capstone projects demonstrate mechanical, manufacturing know-how, leadership skills Cadrex capstone demonstration

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Hero Caption: �� Polytechnic students demonstrate a prototype they created for Cadrex Manufacturing Solutions as part of their senior capstone project.

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John Deere partners with engineering students, faculty on sustainable plastic research

giffeyt — Thu, 09 Apr 2026 13:00:00 +0000

John Deere partners with engineering students, faculty on sustainable plastic researchgiffeyt April 9, 2026

Two-year project seeks to identify recycled polymers that can be used in manufacturing process

Tom Giffey

John Deere machinery has been recognizable for its distinctive green color for more than a century. Student and faculty researchers at �� are working to ensure that John Deere is also known for a different kind of green: sustainability.

Led by Professor Wei Zheng, student research assistants in the B.S. plastics engineering program have been working over the past two academic years to study how John Deere might be able to use recycled plastic polymers to manufacture vehicles.

Zheng is an active member of the Society of Plastics Engineers, and it was through that organization that she formed connections with engineers from John Deere, which is based in Moline, Illinois. The relationship led to a research contract between the Fortune 500 company and ��, which was facilitated by the university ��. Office of Corporate Relations & Economic Engagement.

Beginning in August 2024, students and faculty have tested and molded batches of different types of recycled plastic to see if they meet the manufacturer ��. needs.

“John Deere is asking two key questions,” Zheng said. “Can recycled polymers be used to manufacture these parts? And can those parts meet performance requirements?”

The research is part of the company ��. commitment to incorporating more recyclable and renewable materials into its products so it can be ahead of the curve in its industry, she said.

Student research assistant Ryan Xu measures plastic samples.

Students create, test samples

This semester, two student research assistants have worked on the project. One of them, junior Stephanie Kuhn, explained that the process begins with pellets of different types of recycled plastic polymer that are fed into a massive injection molding machine in the Plastics Engineering Lab inside Jarvis Hall Technology Wing.

Heat and friction melt the pellets, which are forced into a mold where they take the desired shape. Once completed, these pieces are cut precisely into various testing specimens by Instrument Shop Supervisor John Buss, who also assists with machine-related issues.

Next, students subject the specimens to a range of tests, including evaluating their short- and long-term mechanical behavior under stress, as well as their thermal and physical properties to assess overall performance.

Kuhn, who is pursuing a double major in B.S. plastics engineering and B.S. mechanical engineering, said having an opportunity to do this kind of work as an undergraduate is what attracted her to ��.

“I just love being able to use all the machines hands-on. It helps being able to see and use the equipment,” Kuhn said. While already familiar with the injection units and testing equipment from her coursework, taking part in the research helped Kuhn better understand how the equipment operates, reinforcing what she learned.

Likewise, the importance of the research has been highlighted by Kuhn ��. classwork, which has emphasized the need for increasing the use of recyclable plastics. “It has definitely opened my eyes that we need to learn to be more sustainable,” she said. “If John Deere begins to use this, hopefully other manufacturers will, too.”

Sabbatical recap: Wei Zheng, Plastics Engineering, 2024-25

Building biodegradable, sustainable plastics

This semester ��. other research assistant, Ryan Xu, a Menomonie High School senior who is already taking classes at ��, said he appreciates the applied nature of the project, including being able to use advanced equipment and analyze data.

Professor Adam Kramschuster has also helped with the John Deere research project by setting up, optimizing and troubleshooting the injection molding process for manufacturing the samples. This work has involved training the student research assistants and helping with the machine during the molding trials.

“I love working with students. It ��. why I am here, and I enjoy it when they learn and take responsibility as their knowledge base grows,” Kramschuster said.

“Our labs are exceptional,” he continued, “and the opportunity to use them for industry projects is ideal in that the students get even more real-world training during their undergraduate experience.”

Student research assistants Ryan Xu, left, and Stephanie Kuhn work with an injection molding machine in ��'s Plastics Engineering Lab.

Sustainability key to professor ��. research

The kind of research happening in the Plastics Engineering Lab isn’t uncommon at ��. In fact, applied learning and research are among the pillars of the university ��. polytechnic identity, which also include business and industry collaboration and career-focused experience – all three of which are part of the John Deere project.

Zheng noted that two of her prior research assistants leveraged their experience on the project to find jobs in the plastics industry at EVCO and Phillips Medisize. “This project helped them to solidify their injection molding and material testing skills, giving them a clear advantage in the job market,” she said.

The research, she added, will continue through at least this August. “John Deere is quite pleased with the results we have generated so far,” she said. “John Deere has been very supportive throughout the process, including providing Stout the plaque mold and materials, as well as sharing their technical expertise. They even connected us with material suppliers and molders.”

Zheng ��. work on behalf of John Deere complements her ongoing research focus on sustainability. During the 2024-25 academic year, Zheng conducted sabbatical research in advancing sustainability in the field of plastics, focusing on the biodegradation of plastic materials and the recycling of thermosetting materials. Typically, thermoset plastics have undergone a curing process that prevents them from being remelted or reshaped, posing a challenge in the recycling process. However, plastics engineers and chemists researching the reverse crosslinking process are developing ways to break the chemical bonds, allowing thermosetting plastics to be recycled. Part of Zheng ��. research focused on finding ways to reverse the process, increasing the recyclability of this kind of plastic.

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Hero Caption: Student research assistants Stephanie Kuhn, left, and Ryan Xu hold samples in front of an injection molding machine in ��'s Plastics Engineering Lab.

Wei Zheng

Dr. Zheng is an Associate Professor and Program Director of the Plastics Engineering Program at University of Wisconsin-Stout. Prior to joining ��, she was a Postdoctoral Researcher in the Polymer Science and Engineering Department at University of Massachusetts-Amherst. She received a Ph.D. in Chemical Engineering from Texas Tech University in 2008. She is the recipient of several state-funded grants including the WiSys Applied Research Grant and the G. A. Taft Professorship of ��.

Her current research focuses on the bio- and/or biodegradable polymers including rheology of polymer melts and glasses, physics of crystallization and glass transition, curing kinetics of reversible thermosets, and structure-property-processing relationship. She has published 32 refereed articles with more than 700 citations. Dr. Zheng has also been active in the Society of Plastics Engineers (SPE) including serving as the Councilor of the Applied Rheology Division of SPE and the President of Chinese American Society of Plastics Engineers.

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Solutions for space debris, cybersecurity threats among students’ applied research topics at state Capitol

giffeyt — Thu, 12 Mar 2026 18:57:03 +0000

Solutions for space debris, cybersecurity threats among students’ applied research topics at state Capitolgiffeyt March 12, 2026

Undergraduates demonstrate applied learning at annual Research in the Rotunda event

Tom Giffey

From the depths of outer space to the cutting edge of cyberspace, �� undergraduates presented wide-ranging, impactful research March 11 at the annual Research in the Rotunda event in the Wisconsin State Capitol in Madison.

The event embodies �� . polytechnic approach on a statewide stage, with student and their faculty advisers sharing the tangible implications of their applied research in multiple disciplines, including chemistry, cybersecurity, conservation, packaging and human development.

“It ��. one of the more significant events students can go to where they can experience that they are an expert,” said Professor Tina Lee, who has accompanied applied social science students to Research in the Rotunda for more than a decade. Over the years, Lee has watched as student researchers have developed professional confidence presenting their research under the Capitol dome.

Nine outstanding �� undergraduates were among the roughly 125 students from all 13 Universities of Wisconsin campuses who shared their research at the 22nd annual event, which celebrates the positive economic impact of the state ��. universities. Elected officials, policymakers and business leaders were among the hundreds of visitors who explored the displays, chatting with undergraduates and their faculty advisers. Gov. Tony Evers was in attendance, as was Universities of Wisconsin President Jay Rothman, who visited with �� researchers.

“Undergraduate research transforms learning,” as undergraduates apply innovative thinking, data analysis and problem solving to identify solutions, Rothman said.

“In doing so, our students gain exactly the skills that employers across Wisconsin need,” he said. “In short, these research experiences make our universities an even stronger pipeline of great talent.”

�� chemistry major Reese Hufnagel speaks about her work on space debris at Research in the Rotunda.

Bringing space research down to earth

Among the stratosphere-scraping undergraduate talent was �� junior Reese Hufnagel, a B.S. chemistry major who, alongside faculty adviser Professor Matthew Ray, is trying to solve the problem of reentry debris from spacecraft and satellites.

Ideally, materials such as expendable rocket stages and decommissioned satellites burn up when they fall back to earth. However, as stronger carbon-fiber materials have become more common and the number of rocket launches has increased exponentially thanks to firms like SpaceX, reentry debris has become much more common in recent years, Hufnagel explained. To address this potential danger, Hufnagel and Ray have worked to create a catalytic additive that, when integrated into carbon-fiber materials, can cause them to disintegrate when they reach a specific trigger temperature at reentry.

“I think this research is really important because it could solve one of the major issues that is being faced by the aerospace industry today,” Hufnagel said. Entities such as the European Union and the European Space Agency are at the forefront of this topic, the latter having created a Zero Debris Charter that calls for an end to space debris by 2030. “This research is a direct correlation with some of their goals and could significantly impact how people look at ‘design for demise’ when it comes to aerospace,” Hufnagel added.

To bolster their work, Hufnagel and Ray have conducted more than 50 interviews with people in the space industry, including experts at NASA, SpaceX and Sierra Space, which has a facility in Wisconsin. Among other things, the pair have formed a startup to commercialize their work, and Hufnagel has received a research scholarship from the Wisconsin Space Grant Consortium.

As Wisconsin ��. ��, �� uses the slogan “Do More on Day One,” and Hufnagel jokes she began her research on “Day Negative Two” — the weekend before she even started classes.

“I don’t think that ��. something you could do at another university,” she said. “I immediately got attention from people high up, like faculty, who were able to make those kinds of decisions. I was able to start right away as an 18-year-old, starting some of this research and having access to all of the labs.”

Cybersecurity majors Fletcher Meyer, left, and Chloe Kaneski stand by their display about the use of AI agents in cybersecurity.

Keeping an eye on AI agents

Two other �� undergraduates, senior Chloe Kaneski and junior Fletcher Meyer, have also researched ways to mitigate risky incidents, but in a very different kind of space. The B.S. cybersecurity majors’ work focused on using artificial intelligence agents to respond to cybersecurity threats.

Using a large language model (LLM) — specifically, one developed by Anthropic — the students programmed an AI agent to find and fix vulnerabilities in an IT system. The results were measured in terms of correctness, accuracy, effectiveness and other factors. They found that the agent could correctly identify vulnerabilities 74% of the time, but was less accurate (67%) in understanding the vulnerabilities.

“The result of the research was that there should always be a human element,” Meyer said. The AI agent, he explained, would sometimes harm a network while attempting to secure it — for example, by locking itself out without providing a means back in. “So while it can do things at great speed and great quality, there are things that — when it doesn’t match up — it does a very bad job at, and there need to be humans to validate its answers,” he added.

Kaneski said she expects her experience researching and working with AI will be an asset in the professional world.

“Especially in cybersecurity, AI is becoming a pretty big factor, so having exposure to it is going to be a good thing in the long run,” Kaneski said. “It could be valuable to employers if you can see if the tool is effective or not effective.”

Students from across all 13 Universities of Wisconsin campuses took part in Research in the Rotunda on March 11, 2026.

Research explores multiple disciplines

Participants in Research in the Rotunda are nominated by faculty, staff and a student committee. Here is a complete list of this year ��. �� student researchers, their topics and their mentors:

Helayna Brown, of Menomonie, and Ella Kemp, of Cedar Rapids, Iowa, both applied social science: Return on Investment of the Work of County Land and Water Conservation Departments in Wisconsin. Mentors: Professor Tina Lee and Assistant Professor Nicole Hayes.
Cayanna Erickson, of Eau Claire, environmental science: Monitoring the Zebra Mussel Invasion in Lake Menomin. Mentors: Lecturer Julia Chapman and Hayes.
Reese Hufnagel, of Anoka, Minnesota, chemistry: The Sky is Falling: Accelerating Demise During Uncontrolled Reentry of Space Debris. Mentor: Professor Matthew Ray.
Elias Jeska, of Somerset, environmental science: Microcystin Concentrations and Space: A Survey of Spatial and Depth Patterns. Mentor: Hayes.
Louis Malais, of Rhinelander, human development and family studies: The Effects of Traumatic Stress on Interpersonal Relationship Characteristics. Mentor: Associate Professor Kevin Doll.
Fletcher Meyer, of Appleton, and Chloe Kaneski, of Plymouth, Minnesota, both cybersecurity: Autonomous Al Agent for Incident Response. Mentor: Professor Holly Yuan.
Lauren Ras, of St. Michael, Minnesota, packaging: Raspberry Packaging Design: Effects of Air Flow Rate on Raspberry Shelf Life. Mentor: Assistant Professor Mary Paz Alvarez Valverde.

Research in the Rotunda is sponsored by Kwik Trip, Wisconsin Manufacturers & Commerce, BioForward, the Wisconsin Technology Council, the Wisconsin Alumni Research Foundation and the UW-Milwaukee Research Foundation.

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Hero Caption: �� environmental science major Cayanna Erickson speaks about her research on the zebra mussel infestation in Lake Menomin at Research in the Rotunda on March 11, 2026.

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Investigate. Collaborate. Disseminate.

The mission of the Office of Research & Sponsored Programs (ORSP) at Wisconsin ��. polytechnic university is to create and support a university culture that promotes research and assists the �� Polytechnic community in securing the funds to advance research, scholarship, industry collaboration, and other innovations.

ORSP offers support to faculty, staff, and students in their research endeavors. We guide researchers through the pre-award funding process, offering support in proposal development, budget development, and submission. Read on to learn more about our services.

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�� Polytechnic partners with a number of state, foundational, and federal sponsors, including but not limited to, the following (in alphabetical order):

3M Foundation
American Lung Association
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Margaret A. Cargill Foundation
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United States Department of Commerce
United States Department of Defense
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West Central Wisconsin Workforce Development Board
Wisconsin Department of Workforce Development
Wisconsin Economic Development Corporation
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Creek restoration, data center viewpoints, sustainability researched by LAKES REU students

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Engineering students support Sierra Space ��. lunar testing system

Alum works with engineering students to improve lunar dust testing, bolstering NASA ��. return to the moon

Red Cedar Basin Monitoring Group trains next generation of water scientists

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Building with air – how nature ��. hole-filled blueprints shape manufacturing

hugginsm — Thu, 05 Feb 2026 17:29:24 +0000

Building with air – how nature ��. hole-filled blueprints shape manufacturinghugginsm February 5, 2026

Professor Anne Schmitz examines the influence of the natural world on engineering and additive manufacturing.

Anne Schmitz

This article appeared in TechXplore and others, and originated from The Conversation, an independent and nonprofit source of news, analysis and commentary from academic experts.

If you break open a chicken bone, you won’t find a solid mass of white material inside. Instead, you will see a complex, spongelike network of tiny struts and pillars, and a lot of empty space.

It looks fragile, yet that internal structure allows a bird ��. wing to withstand high winds while remaining light enough for flight. Nature rarely builds with solid blocks. Instead, it builds with clever, porous patterns to maximize strength while minimizing weight.

Cross-section of the bone of a bird ��. skull: Holes keep the material light enough that the bird can fly, but it ��. still sturdy. Steve Gschmeissner/Science Photo Library via Getty Images

Human engineers have always envied this efficiency. You can see it in the hexagonal perfection of a honeycomb, which uses the least amount of wax to store the most honey, and in the internal spiraling architecture of seashells that resist crushing pressures.

For centuries, however, manufacturing limitations meant engineers couldn’t easily copy these natural designs. Traditional manufacturing has usually been subtractive, meaning it starts with a heavy block of metal that is carved down, or formative, which entails pouring liquid plastic into a mold. Neither method can easily create complex, spongelike interiors hidden inside a solid shell.

Bird bones, seashells and honeycombs use clever, porous designs to stay strong without the extra weight. Now, 3D printing is letting engineers copy those natural blueprints.

The sustainable future

Beyond performance, mimicking nature ��. less-is-more approach is a significant win for sustainability. By “printing air” into the internal structure of a product, manufacturers can use significantly less raw material while maintaining the necessary strength.

As industrial 3D printing becomes faster and cheaper, manufacturing will move further away from the solid-block era and closer to the elegant efficiency of the biological world. Nature has spent millions of years perfecting these blueprints through evolution – and engineers are finally learning how to read them.

The invisible architecture

That paradigm changed with the maturation of additive manufacturing, commonly known as 3D printing, when it evolved from a niche prototyping tool into a robust industrial force. While the technology was first patented in the 1980s, it truly took off over the past decade as it became capable of producing end-use parts for high-stakes industries like aerospace and health care.

3D printing makes it far easier to manufacture lightweight, hole-filled materials. kynny/iStock via Getty Images

Instead of cutting away material, printers build objects layer by layer, depositing plastic or metal powder only exactly where it ��. needed based on a digital file. This technology unlocked a new frontier in materials science focused on mesostructures.

A mesostructure represents the in-between scale. It is not the microscopic atomic makeup of the material, nor is it the macroscopic overall shape of the object, like a whole shoe. It is the internal architecture, including the engineered pattern of air and material hidden inside.

It ��. the difference between a solid brick and the intricate iron latticework of the Eiffel Tower. Both are strong, but one uses vastly less material to achieve that strength because of how the empty space is arranged.

If engineers wanted to make a part stronger, they generally had to make it thicker and heavier. This approach is often inefficient, wastes material and results in heavier products that require more energy to transport.

I am a mechanical engineer and associate professor at the University of Wisconsin-Stout, where I research the intersection of advanced manufacturing and biology. For several years, my work has focused on using additive manufacturing to create materials that, like a bird ��. wing, are both incredibly light and capable of handling intense physical stress. While these “holey” designs have existed in nature for millions of years, it is only recently that 3D printing has made it possible for us to replicate them in the lab.

From the lab to your closet

While the concept of using additive manufacturing to create parts that take advantage of mesostructures started in research labs around the year 2000, consumers are now seeing these bio-inspired designs in everyday products.

The footwear industry is a prime example. If you look closely at the soles of certain high-end running shoes, you won’t see a solid block of foam. Instead, you will see a complex, weblike lattice structure that looks suspiciously like the inside of a bird bone. This printed design mimics the springiness and weight distribution found in natural porous structures, offering tuned performance that solid foam cannot match.

Engineers use the same principle to improve safety gear. Modern bike helmets and football helmet liners are beginning to replace traditional foam padding with 3D-printed lattices. These tiny, repeating jungle gym structures are designed to crumple and rebound to absorb the energy more efficiently than solid materials, much like how the porous bone inside your own skull protects your brain.

Testing the limits

In my research, I look for the rules nature uses to build strong objects.

For example, seashells are tough because they are built like a brick wall, with hard mineral blocks held together by a thin layer of stretchy glue. This pattern allows the hard bricks to slide past each other instead of snapping when put under pressure. The shell absorbs energy and stops cracks from spreading, which makes the final structure much tougher than a solid piece of the same material.

I use advanced computer models to crush thousands of virtual designs to see exactly when and how they fail. I have even used neural networks, a type of artificial intelligence, to find the best patterns for absorbing energy.

My studies have shown that a wavy design can be very effective, especially when we fine-tune the thickness of the lines and the number of turns in the pattern. By finding these perfect combinations, we can design products that fail gradually and safely – much like the crumple zone on the front of a car.

By understanding the mechanics of these structures, engineers can tailor them for specific jobs, making one area of a product stiff and another area flexible within a single continuous printed part.

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Ashley Furniture-sponsored project results in ‘better product’ developed by engineering seniors

goersab — Mon, 05 Jan 2026 13:50:00 +0000

Ashley Furniture-sponsored project results in ‘better product’ developed by engineering seniorsgoersab January 5, 2026

Student team builds functional nonstandard pallet stacker to be implemented, replicated in company ��. facilities

Abbey Goers

A team of engineering students at �� designed an innovative nonstandard pallet stacker for Arcadia-based Ashley Furniture, which plans to quickly implement the machine in its facilities.

Within their Senior Design Experience II capstone course, the team was tasked with building a machine that could lift and hold 6-foot-long, 100-pound pallets off the ground until a stack of 12 was collected. Made of quarter-inch steel, the stacker can support 1,800 pounds, a 125% increase of Ashley ��. requested 1,400 maximum stack weight.

Once the stack is complete, the system lowers it to the floor for removal with an electric pallet jack. The stacker – which is 10 feet long, 8 feet wide and 4 feet tall – can be operated by a single person and has a maximum cycle time of 40 seconds.

Erik Kramer, Chase Rodewald, Luke Mertens, Riley Stiehl and Zachary Morgan.

The student team is Luke Mertens, a double major in manufacturing and mechanical engineering from Blue Earth, Minnesota; manufacturing engineering major Zachary Morgan of Eau Claire; and mechanical engineering majors Chase Rodewald of Lake City, Minnesota, and Riley Stiehl of Alma.

During the Manufacturing Engineering & Mechanical Engineering Showcase on Dec. 16, they presented a scaled, controls-focused prototype to �� faculty and supporters, as well as Ashley representatives, including Manufacturing Engineer Erik Kramer, the team ��. project manager.

“The �� team built a better system, a better product for us. And with a final product price of about $25,000, their solution offers us a cost reduction of about 60%,” Kramer said. “Now, with the team ��. documentation, our automation team can replicate their functional design to build six more stackers for our facilities.”

Riley Stiehl (left) and Chase Rodewald (right) present the Ashley Furniture nonstandard pallet stacker.

The team will submit their accompanying documents and the full-size machine, which includes an emergency stop for user safety, to Ashley for integration into the company ��. operations. Final assembly will be completed at Ashley, when safety curtains will be installed around the machine as well.

Reverse-engineering to build a better product

The two-semester-long project began last spring, when the team had a site visit to Ashley to meet with Kramer and other staff. Ashley had purchased a stacker from a third party, but there were aspects of the machine that Kramer and staff didn’t like.

“We needed the Stout team to find a way to reverse-engineer the machine to have it function as we needed it to,” Kramer said.

A digital SolidWorks model of the Ashley Furniture nonstandard pallet stacker.

The team developed schematics in SolidWorks software and a small-scale model, which they presented to Ashley in May. Ashley purchased the materials needed to build the prototype as well as the final product.

“We’re no different than a real engineering team. Everyone is working together, but we each have niche roles based on our strengths,” said Mertens, who led the team ��. controls and instrumentation. Morgan was the CNC machinist and completed the documentation and organization of project records. Rodewald and Stiehl managed the manual assembly, machining and welding.

While some of the parts were cut and machined at Ashley, the team also completed the machining and welding of parts in �� . Fryklund Hall labs.

Chase Rodewald (left) and Riley Stiehl (right) assemble the Ashley Furniture nonstandard pallet stacker prototype.

“There ��. a lot to be done, so it ��. nice to have multiple people working on it together,” Stiehl said. “We relied on Ashley ��. industry equipment and experience. Having them cut and machine parts, rather than going to a third source, was a lot more cost-effective and saved a lot of time. And we could also use our own skills right in the labs on campus.”

Electrical and welding breakthroughs

During the first phase of their project, the team ��. biggest challenge was how to meet one of the requirements set by Ashley: using electrical power, rather than pneumatics or hydraulics, to lift the pallets.

“Because most electrical motors are rotational based, it limits your options for linear motion, or the straight-line and up-and-down motion we needed for the pallet stacker,” Rodewald said. “We achieved this through a linear actuator, which is a device that converts a motor ��. rotational energy into linear motion.”

Luke Mertens works on the controls for the Ashley Furniture nonstandard pallet stacker prototype.

The electrical power matches Ashley ��. capabilities and can be implemented immediately on the shop floor by pulling in power from overhead sources, instead of the company having to install tanks to support a fluid power device.

During the project ��. second phase, the team was challenged by how to weld some of the individual pieces before final assembly. The gussets – a three-part support structure, for example – needed to self-align at a 90-degree-angle to make it easier for Rodewald and Stiehl when welding the pieces together.

“We devised a self-aligning slot and tab mechanism, so the parts would basically hold themselves in place,” Stiehl said.

A side-by-side comparison of a digital model and a welded gusset.

“Breakthroughs often come just after the moment you feel you’ve exhausted every option,” Mertens added.

Engineering students use a project management methodology called a “stage gate process,” which includes built-in briefs and reviews at key points in the design and build process. It also allows for feedback from their classmates, professors and project sponsors.

“The process is very helpful because it allows you to review the current aspects of your design, so you never get too far down a rabbit hole,” Mertens said. “The feedback allows for a varying array of perspectives from your rough draft to the final draft of your concept.”

Zachary Morgan (left) and Luke Mertens (right) present a prototype of the Ashley Furniture nonstandard pallet stacker.

This fall semester, the Ashley capstone team was just one of a dozen teams composed of about 50 engineering students working on Capstone I and II projects in Fryklund Hall labs.

Mertens, Morgan, Rodewald and Stiehl earned their degrees and crossed the commencement stage on Dec. 20, among a class of 527 Stout Proud graduates.

According to the university ��. most recent First Destination Report, 99% of 2023-24 graduates from the mechanical and manufacturing engineering programs reported they were either employed or continuing their education within six months, with an average starting salary of $72,000.

�� . Robert F. Cervenka School of Engineering is home to five ABET-accredited programs that also include computer and electrical engineering, engineering technology and plastics engineering, as well as a sixth bachelor ��. program in packaging. A master ��. in manufacturing engineering is available on campus or online.

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Sustainability packaging helps Madison's Tricky Foods ship charcuterie, cheese boards coast to coast

giffeyt — Wed, 17 Dec 2025 14:00:00 +0000

Sustainability packaging helps Madison's Tricky Foods ship charcuterie, cheese boards coast to coastgiffeyt December 17, 2025

Packaging professor and student identify sustainable insulation option

Tom Giffey

Faculty-student research conducted this fall in University of Wisconsin-Stout packaging labs is poised to help a Wisconsin business deliver its tasty but temperature-sensitive goods coast to coast.

Associate Professor Xiaojing “Kate” Liu of �� . packaging program worked with Madison-based Tricky Foods to test the insulating abilities of two eco-friendly packaging options – one made of cornstarch, the other of recycled paper. The goal: To determine the best way to keep the cheese, meat and other perishables on the company ��. charcuterie boards fresh while in transit.

Therese Merkel, owner of Tricky Foods, worked closely with Liu for months and is confident that the research-backed expertise that she ��. received – and the custom-made packing materials she ordered based on that expertise – will help her small business break into the long-distance delivery market.

“Kate is the only reason I’m able to launch this thing so quickly,” Merkel said in an interview from her Madison office. “She has been the backbone of the entire project.”

Tricky Foods owner Therese Merkel, left, and Assistant Professor Kate Liu collaborate in ��'s packaging lab. / Submitted photo

Research will aid business expansion

Merkel started Tricky Foods in her home kitchen during the midst of the COVID-19 pandemic in 2020. Thanks to her charcuterie boards filled with sliced meats, Wisconsin cheeses, fresh and dried fruits, honey, jams, nuts, and more, the business grew rapidly, and now Merkel has a storefront and 12 employees. But her ability to continue to scale up the business collided with her inability to figure out how to safely ship her goods long distances, despite customers’ requests.

“We’ve had people asking us to ship since 2020. I thought, ‘Oh, I’ll work on it when it slows down,’ and I never got around to it,” she explained.

The route around her business roadblock began when she joined a business accelerator program operated by StartingBlock, a nonprofit regional startup hub and coworking space in Madison.

“Because Therese ��. products are perishable and have a very clear aesthetic, it was clear that she needed to work with packaging experts,” said Scott Mosley, CEO of StartingBlock. “As the state ��. only polytechnic and the only school to have a dedicated packaging program, it was natural to recommend that Therese contact ��.”

Merkel reached out to �� . Office of Corporate Relations & Economic Engagement, which works to connect university resources to business, industry and community stakeholders. Seth Hudson, �� . executive director for corporate relations and economic engagement, put her in touch with Liu.

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A sample charcuterie board prepared by Tricky Foods. / Submitted photo

Before partnering with Liu at ��, Merkel explained, “Nobody wanted to work with me because I’m too small at this point. I didn’t have a huge budget to pay someone to help me design something.” However, Liu was willing to collaborate, connecting frequently through video calls to ask questions and show packaging samples. Ultimately, she invited Merkel to visit �� to examine prototypes firsthand, which she did in September.

Once they settled on the optimal packaging – 1.5-inch-thick biodegradable foam insulation, which dissolves in water, wrapped in recyclable plastic and accompanied by 64- to 80-ounce cold gels – Liu helped Merkel identify vendors who could custom-make what she needed.

“I enjoyed it a lot,” Liu said of the collaboration. “(It was) especially satisfying to see the solution carried out and help Tricky Foods’ business.”

Liu said she is confident that the packaging solution will meet Merkel ��. needs, and she added that part of the research results will be published in a peer-reviewed article and presented at an international packaging conference in 2026.

Merkel expects to begin test-shipping products using the new packaging this Christmas season, and she ��. optimistic about the results and the impact on her business. “Next year will definitely be our biggest year ever,” she said.

The efficacy of sustainable packing materials, including cornstarch and recycled paper options (center), were tested at ��.

Impactful undergraduate research

�� is one of only a few schools in the United States, and the only school in the Universities of Wisconsin, that offers a B.S. in packaging program.

Liu ��. lab assistant for the research is Claire Le, a sophomore packaging major from Phu Quoc City, Vietnam. Le said she didn’t expect to be doing such impactful research so early in her college career. “It ��. been challenging, but in the best way,” she said. “I’ve learned a lot about experimental design, budgeting, troubleshooting and presenting results professionally.”

Le said the most interesting part of the project was learning how different kinds of insulating materials behaved in cold-chain conditions. “Testing cornstarch versus fiber liners and tracking how long they keep food under 40°F feels meaningful because we’re working on something that can genuinely impact food safety,” she said.

These packaging options are also more environmentally friendly, replacing products made of polystyrene foam. Repeated lab tests found that cornstarch liners, when combined with cold packs, could keep 5-pound charcuterie boards properly cooled for 48 hours. When sealed correctly, the packages maintain the necessary temperature despite vibrations during transit, which were simulated in the lab with a vibration table that jostled the packages for hours at a time.

“I hope this research gives (Tricky Foods) clear, data-driven recommendations on which insulation material is more reliable for keeping food safe during transport,” Le said. “My goal is for the results to help them make stronger packaging decisions, reduce spoilage and improve their cold-chain performance.”

Merkel called �� a “hidden treasure” because of the expert assistance it can give to businesses like hers.

“For an entrepreneur who ��. new in the e-commerce game, (��) is the difference between me being able to launch this and not,” she said. “Without Kate, I wouldn’t have been able to. I’m just beyond grateful.”

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Packaging professor and student identify sustainable insulation option for small business Tricky Foods owner Therese Merkel and Assistant Professor Kate Liu

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Faculty integrate AI research in machine learning, business technology, composition courses

goersab — Wed, 29 Oct 2025 13:00:00 +0000

Faculty integrate AI research in machine learning, business technology, composition coursesgoersab October 29, 2025

University ��. 360-degree approach to artificial intelligence aims to ‘equip students with hands-on experience and an applied understanding’

Abbey Goers

As �� continues to strengthen its 360-degree approach to artificial intelligence, embedding skills across all programs, faculty experts across degree fields build on their growing knowledge with research spanning generative artificial intelligence (GenAI), machine learning, AI deep research methods and more.

Three professors – Augustine Twumasi, Cami Banger and Justin Nicholes – representing �� . mathematics, statistics and computer science; hospitality and technology innovation; and English, philosophy and communication studies departments – demonstrate the wide range of research topics and challenges they’re tackling through AI to impact their fields and improve their students’ polytechnic experience.

The university ��. AI Fellows and AI Innovation Committee, led by faculty and staff, ensures AI is embedded into learning, operations and innovation, while directing AI integration, governance, ethics and literacy. The interdisciplinary AI Fellows is supported by 2023-25 Workforce Development funding.

Machine learning in engineering and manufacturing

Artificial intelligence and machine learning Assistant Professor Augustine Twumasi ��. research broadly focuses on developing intelligent systems that integrate machine learning, optimization, and physics-based modeling to solve complex engineering and scientific challenges.

Machine learning is a subfield of AI. It is a way for computers to think, learn and act just like humans. As the term “artificial” suggests, this form of intelligence is created by humans. “Machine learning is a way we make computers intelligent and capable of performing such tasks without explicitly teaching them how to do so. It does this by identifying patterns in data,” he said.

“One aspect of my work involves robot path planning in Robotic Compact Storage and Retrieval Systems (RCSRS), where I use reinforcement learning and advanced optimization algorithms to improve retrieval efficiency and scheduling, helping robotic systems make faster and more adaptive decisions in dynamic environments,” Twumasi said.

Another major focus of his research is laser scan path design in Laser Powder Bed Fusion (L-PBF) additive manufacturing. “In this research, I apply deep reinforcement learning and physics-guided machine learning to design toolpaths that control microstructure evolution, to enhance the mechanical performance of printed parts,” he said.

RCSRS are widely used in the logistics, e-commerce, manufacturing, and warehousing industries, particularly in automated fulfillment centers, pharmaceutical inventory systems, grocery distribution and retail supply chains. The systems help optimize storage density, retrieval speed and operational efficiency.

L-PBF technology is central to aerospace, automotive, biomedical, and defense industries, where it is used to produce lightweight, high-strength metal components with complex geometries. It ��. also increasingly applied in energy, tooling and custom medical implants because of its precision ability.

Twumasi ��. current and upcoming projects also explore scientific machine learning, uncertainty quantification, and AI-driven modeling for smart manufacturing and logistics optimization. He hopes to soon recruit student researchers.

GenAI and business technology

Assistant Professor Cami Banger, program director of business information technology and digital marketing technology, is leading a Scholarship of Teaching and Learning (SoTL) study titled “Reimagining Assignment Design: An Exploratory Study of AI-Assisted TILT Implementation.”

“The project explores how instructors can use generative AI to redesign assignments using the Transparency in Learning and Teaching (TILT) framework, which focuses on clarity, grading efficiency and student learning outcomes,” she said.

Banger ��. AI research and teaching intersect around GenAI and its practical implementation in higher education and business technology. She has developed and is currently teaching a professional development course, AI Implementation Strategy, where students design organizational AI strategies aligned to NIST, IBM, and McKinsey frameworks. The course integrates real-world AI tools and showcases how polytechnic learning can connect strategy, ethics and technology practice.

She is incorporating AI across the business information technology and digital marketing technology programs and highlights her research in her article “Generative AI is coming to the workplace, so I designed a business technology class with AI baked in,” published in The Conversation.

“From piloting CoPilot for Business in our capstone course and doing CRM case simulations using Salesforce with GenAI support to reflective assignments on ethical AI use in business, these projects collectively aim to equip students with hands-on experience and an applied understanding of AI in business and technology contexts, which aligns closely with Stout ��. polytechnic mission,” Banger said.

Human vs. GenAI poetry

Associate Professor Justin Nicholes, director of First-Year Composition, explored “Ownership, Accuracy, and Aesthetic Merit” in human and AI-generated poetry.

His research, published earlier this year in “Written Communication,” asked the questions, Would college students judge their poems differently from those written by GenAI? Would they feel a stronger sense of ownership of their writing versus AI-generated poetry?

“With each passing semester and academic year, students’ attitudes and experiences with generative AI change,” Nicholes said. “One surprising result from my research into asking students to write with and without AI through poetry, and about autobiographical moments, is that students increasingly see GenAI as a tool that enhances their personal meaning-making. It is not enough to simply dismiss GenAI writing as a form of cheating. While some will refuse GenAI, especially for personal and creative expression, there is a role, and we need to keep trying to understand how students see GenAI tools and the writing they produce with and without it.”

For his research, Nicholes recruited 88 first-year students, who composed brief poems about meaningful or challenging life experiences, such as loss, pain, anger, disappointment or defeat. They then prompted a GenAI program, such as ChatGPT or Gemini, to compose a poem about that same event.

The students wrote poems that were more narrative, authentic, unguarded and emotionally negative in tone than the GenAI poems.

Following their writing, the students completed surveys to record their perceptions of their own poems and GenAI poems, based on ownership, accuracy and aesthetic merit. Ownership referred to whether the writing reflected an important part of the writers’ selves. Accuracy referred to whether the poem reflected their thoughts and feelings. Aesthetic merit referred to the quality of the writing, with features such as vivid imagery, a feeling of completeness, rhyme, meter, structure and form.

Finally, the students were asked which poem they preferred and why.

Nicholes’ findings showed that the students fairly evenly preferred their poems to the GenAI poems: 42% preferred their poems because of the personal connections to the events; 50% preferred the GenAI poems, mainly for their textual features; and 8% preferred both.

Students felt significantly greater ownership of and accuracy in their human-written poems. And while students rated aesthetic merit higher for GenAI poems, which portrayed greater imagery, language, and form, they felt the GenAI poems lacked originality.

“In terms of implications for teaching writing, meaningful literacy remains a valuable college-writing experience whereby college writers in various writing contexts have chances to create work they view as important parts of themselves, work they see as importantly conveying their life experiences and voices, and work that they see as unique contributions,” Nicholes said. “While GenAI may be used as a tool to assist in autobiographical, meaningful writing, and although it has the potential for assisting writers in ways similar to peer review processes, human creativity is a unique territory worth protecting.”

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�� completes $7.4M lab renovation, improving space for cutting-edge equipment, learning

giffeyt — Tue, 14 Oct 2025 14:00:00 +0000

�� completes $7.4M lab renovation, improving space for cutting-edge equipment, learninggiffeyt October 14, 2025

Changes to Jarvis Tech labs boost engineering, construction programs

Tom Giffey

The final phase of a $7.4 million renovation project has brought crucial upgrades to two of �� . biggest and busiest labs.

The revamp of the Construction Lab, the Woods Lab and adjacent portions of Jarvis Hall Technology Wing was completed over the summer, with the labs fully upgraded by the beginning of the fall semester.

Among the most visible changes are the addition of new windows and large overhead doors that open onto the well-traveled hallway between the labs, a frequent route for students and visitors alike passing through the connected Jarvis Science, Jarvis Tech, Micheels and the Applied Arts buildings.

“The Jarvis Tech renovations will significantly improve the functioning of some of the largest labs on the campus through upgrades in the HVAC system, increased visibility and access to the labs through the addition of roll-up doors and more efficient use of valuable space through reconfiguring lab layouts,” said Daniel Freedman, dean of the College of Science, Technology, Engineering, Mathematics and Management.

$7.4M labs renovation project sheds light on mechanical, plastics engineering

Two large engineering labs and one of the busiest building corridors at �� have fresh, new looks this fall with students back on camp

Phase 1 of the project was completed during the summer of 2024, and encompassed about 17,000 square feet of Jarvis Tech, including the Plastics Engineering Lab and the Engineering Technology Research and Development Lab. The recently completed Phase 2 included nearly 25,000 square feet. The two-phase project was funded as part of the 2021-23 state capital budget.

As Wisconsin ��. ��, �� emphasizes applied learning and provides three times more labs than classrooms. In many cases, as with the newly renovated labs, classroom and lab space are next to each other so that lectures and hands-on applications are seamlessly intertwined.

Chad Schlough, project manager for Facilities Management, said one of the major components of the latest renovation was replacing two air handling units, creating more efficiency and adding greater control. A new dust-collection system and three new exhaust fans in the Construction Lab, which is used extensively by students in the B.S. construction management program, also will improve air quality and environmental safety.

Both labs also received new paint, while in the Woods Lab worn-out parquet flooring made way for polished concrete. Other nearby rooms — including the Construction Conference Room — received upgrades such as new flooring, ceilings and paint.

Students collaborate in the newly renovated Woods Lab.

Other elements of the project included:

The completion of a sprinkler system that now encompasses the entire first floor of Jarvis Tech.

Upgrades to the fire alarm notification system.

Renovations to existing restrooms and the addition of a single-occupant restroom.

The addition of a secure store area for surveying equipment used in site engineering classes.

“This renovation is another step forward for �� . applied learning environment,” said Senior Facilities Officer Justin Utpadel. “The upgrades not only enhance safety and functionality but also increase the visibility and adaptability of our instructional spaces.”

New hallway windows, like these at the Plastics Engineering Lab, have been added to multiple labs in Jarvis Hall Technology Wing in the past two years.

The renovations also created space for two new pieces of state-of-the-art machinery purchased through other funding sources. A newly renovated room will house a $1 million Amatrol Smart Factory Enterprise system donated by the Ronald and Joyce Wanek Foundation. This fully integrated automated manufacturing system includes a manufacturing line composed of processes such as inventory control, inspection, sorting, assembly, testing, CNC machining and storage, all linked by ethernet or wireless communications. The system is designed to showcase how all these technologies are integrated in a modern production system and to educate students in how to build and maintain such systems.

Ronald & Joyce Wanek Foundation donation transforms labs with advanced manufacturing equipment

Machinery for automated manufacturing, 3D printing and more will impact thousands of students’ polytechnic experiences

This equipment, which will be installed in a room adjacent to the Woods Lab, was made possible by a $3.1 million donation from the Ronald and Joyce Wanek Foundation, which was announced in August. The Foundation was established by Ronald Wanek, founder and chairman of Ashley Furniture Industries, LLC, and his wife, Joyce. Their son, Todd Wanek, is a 1988 �� alum and president and CEO of the company.  

Similarly, the renovation made space in the Construction Lab for a 3D concrete printer that will be installed later this academic year. That device was purchased through a $647,000 grant from the Wisconsin Economic Development Corp. announced last spring for �� . Center for Advanced Manufacturing and Artificial Intelligence (CAM-AI).

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Ronald & Joyce Wanek Foundation donation transforms labs with advanced manufacturing equipment

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Changes to Jarvis Tech labs boost engineering, construction programs Two students in Wood Lab

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Food science graduate students’ protein-packed candy, cottage cheese creations earn accolades

giffeyt — Fri, 01 Aug 2025 16:44:47 +0000

Food science graduate students’ protein-packed candy, cottage cheese creations earn accoladesgiffeyt August 1, 2025

Algae-infused treat wins People ��. Choice Award at statewide WiSys event

Tom Giffey

A stroll down the aisle of the supermarket or a scroll through your social media feed likely provides plenty of evidence that when it comes to consumer products and nutritional advice, protein is all the rage.

Sales of traditional protein-rich foods like beef have soared, and whey – once an afterthought to the dairy industry – is now a hot commodity. Protein is being packed into everything from waffles to popcorn to soda, and The New York Times recently declared that there is a “protein bar arms race” underway.

And consumers are buying in: Research by Minnesota-based Cargill published earlier this year found that 61% of Americans surveyed reported they boosted their protein intake last year.

This summer, two protein-packed products created by University of Wisconsin-Stout graduate students – one a hard candy made with green algae, the other a celery-infuse cottage cheese – earned accolades. Both research projects were supported by the Evelyn Van Donk Steenbock Endowed Chair grant awarded to Associate Professor Pranabendu Mitra of the university ��. Kinesiology, Health, Food & Nutritional Sciences Department.

One of the award winners is �� graduate student Prachi Sakariya, who is pursuing her M.S. in food science and technology. Prachi has noticed the protein trend, but she also knows about the environmental implications of the dominant sources of protein, both animal- and plant-based. She received the People ��. Choice Award at the WiSys Quick Pitch State Final in Madison, part of the WiSys SPARK Symposium, which ran July 23-25.

Another �� food science and technology graduate student also received recognition for her research this summer. Durga Bhavani Mahankali won second place for an oral presentation she delivered in the product development division at the Institute of Food Technologists’ FIRST Annual Event & Expo in Chicago July 13-16.

Samples of algae-infused candy made with Chlorella and Spirulina. / Submitted photo

Earth-friendly candy creation

“Whey protein requires a lot of water and a lot of animal milk, and on the other hand plant protein like soy also requires a lot of land, which has resulted in deforestation,” Prachi said. “Right now, water and land use may not seem like a critical concern globally, but over the next few decades, as drinking water and cultivable land shrink, these will become serious challenges. That ��. where algae could play a significant role.”

Microalgae such as Chlorella and Spirulina absorb carbon dioxide from the environment, take comparatively little land and water to grow, and have a 60% to 70% protein content, she explained. Yet despite their benefits, microalgae are used in relatively few consumer products.

Prachi aimed to change that by creating a unique product that meets consumers’ desires for both extra protein and sweet treats: a microalgae-infused hard candy she calls an “algae pop.” After experimenting with various recipes, Prachi settled on a 50-50 mix of the two varieties of microalgae combined with sucrose, glucose, lime and citric acid, creating a dark-green candy with a refreshing lime-like flavor.

The project began as an assignment in Mitra ��. food product development class last fall. After research, lab work and sensory analysis by 60 campus volunteers, Prachi presented her innovative idea at �� . WiSys Quick Pitch competition in early May. She won first place at the competition, held in conjunction with �� . annual Research Day.

Prachi, center, won first place at ��'s Quick Pitch competition in May. She is shown with Chancellor Katherine Frank, right, and Provost Glendalí Rodríguez.

The campus success allowed her to move forward to the WiSys Quick Pitch State Final on July 25. Out of approximately 275 registered attendees, Prachi ��. pitch received the most audience votes.

“It was a wonderful experience to win first place at Stout and then to receive the People ��. Choice Award at the state-level competition,” she said. “It truly encouraged me, and it was very exciting to present my idea beyond the classroom to professional researchers and innovators.”

While her prior academic career – which includes B.S. and M.S. degrees in her native India – prepared Prachi for the meticulous lab work required for the project, she said that participating in the pitch competition helped her gain valuable experience in presenting her ideas to a broader audience, notably by condensing her research into a three-minute pitch. Prachi credits Mitra with helping her practice and overcome her stage fright.

Currently, her research remains at the lab level, but Prachi plans to further enhance the product by improving the flavor and increasing its protein content. Based on the strong interest shown by attendees at the event, she is now in discussions with a WiSys innovation advisor about future development and potential commercialization.

WiSys is an independent nonprofit that serves as a technology transfer office for Universities of Wisconsin campuses such as ��.

�� graduate student Durga Bhavani Mahankali, third from right, with �� colleagues at the IFT FIRST expo in Chicago. / Submitted photo

Giving cottage cheese a nutritional boost

Mahankali ��. presentation at the IFT expo in Chicago focused on a project – which was also developed in Mitra ��. food science and technology research course – that created cottage cheese infused with celery.

Mitra, her professor, described IFT as the “biggest, largest and most prestigious conference for food scientists in the world.” Taking part allows students to network with others in the industry for possible job opportunities.

“Our research mainly focused on making a product that not only tastes good but also offers health benefits,” Mahankali explained. “The idea aligns very well with growing consumer interest in functional foods, which makes our idea stronger.”

Durga Bhavani Mahankali poses with the IFT FIRST expo sign in Chicago. / Submitted image / Submitted photo

Driven in part by social media buzz, cottage cheese has surged in popularity, she said. Cottage cheese is already low in fat and high in protein, and adding celery infuses it with antioxidant and anti-inflammatory properties because of vitamins A and D. Mahankali said a mixture with 9% celery was found to be most promising as a commercial product.

“One of our professors even mentioned that he would buy the product if it were available on the market,” she said.

Mahankali was the primary investigator on a six-member team that included fellow graduate students Valluru Varun Naga Sai, Durga Siva Rama Krishna Gokavarapu, Sreeya Peri, Sai Sri Mamillapalli and Ganesh Allu. While the entire team was able to attend the conference, it was Mahankali who gave the six-minute presentation to an audience of judges, industry professionals, professors and fellow students. She then answered the judges’ questions about the product ��. potential shelf-life and cohesiveness.

“It was a great opportunity to discuss my work in-depth and show how it addresses current trends in functional foods,” Mahankali said.

“It was my dream to attend the IFT conference, and now winning an award on this stage means a lot to me,” she added. “It ��. not just mine and my team ��. hard work but our mentor (Dr. Mitra) who always motivated and guided us in the right way.”

Associated Professor Pranabendu Mitra received the �� Outstanding Research Mentor Award in May.

Adding communication abilities to lab skills

Mitra, whose own research focuses in part on environmental sustainability in the food industry, is proud of his students who have had success at the Quick Pitch and elsewhere. In 2023, Stout alumnus Areeba Ali won first place and the People ��. Choice Award for “Development of Eco-friendly Milk Whey Protein Isolate Biodegradable Packaging.” And M.S. food science and technology graduate Josh Bernin took second place in the Quick Pitch state finals in 2022 for his presentation, “Developing Protein Rich Higher Fiber and Antioxidant Cranberry Pomace Infused Soy Flour and Rice Flour Blend Extruded Fried Snack.”

Mitra said he strongly encourages his students to take part in competitions such as these. Many food science graduates find jobs in quality assurance or product development, professions that will require them to communicate with coworkers, regulators and customers. Food scientists, Mitra emphasized, need both lab skills and communication skills to have professional success.

“Although you have a strong background in lab skills, if you cannot communicate what you are doing, nobody knows what you are doing,” said Mitra, whose commitment to facilitating student research earned him the annual �� Outstanding Research Mentor Award last spring.

Food science graduate student Areeba Ali wins WiSys Quick Pitch state title, People ��. Choice

Research into sustainable packaging made from milk protein inspired by Wisconsin ��. dairy-rich identity

Mitra praised Prachi for working hard in the lab to formulate her algae pop as well as outside of class to hone her public speaking.

Likewise, Prachi thanked Mitra, her advisor, for his encouragement, and also highlighted the support of the university ��. Office of Research and Sponsored Programs, a partner with WiSys in backing the Quick Pitch competition.

ORSP supports students, faculty, staff and the institution overall in their research endeavors. The office provides funding to support research and creative activity and attendance of research conferences, coordinates �� . annual Research Day, and recognizes outstanding research through an annual award program, among other activities.

“The applied research that Stout students participate in not only challenges them to solve real-world problems and develop innovative product ideas, like Prachi ��. protein-infused candy, it leads them to develop professional communication skills to share their work broadly – with peer researchers, academia and industry,” said Research Program Coordinator Chela Cea of the ORSP. “As the winner of our campus Quick Pitch competition, held on Research Day each year, we were so proud to have Prachi represent �� at the state level. Her research, supported by our outstanding faculty, and persuasive pitch clearly resonated with attendees and potential industry partners.”

Prachi, who will begin her second year at �� in the fall semester, looks forward to continuing work on her product and career goals.

“�� always pushes students toward not only the theoretical basis but also to learn about the practical version of food science,” she said.

Algae-infused treat wins People ��. Choice Award at statewide WiSys event Prachi pours algae candy mixture in lab

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M.S. Food Science & Technology

Our M.S. Food Science & Technology program will prepare you for a future as a food technologists/leaders through education, research, and outreach.

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Hero Caption: �� graduate student Prachi Sakariya creates a batch of algae-infused candy in the lab. / Submitted photo

Pranabendu Mitra

Dr. Mitra is an Assistant Professor in the Department of Food and Nutrition. He is a Professional Engineer (P. Eng., APEGS, Canada). He received his Bachelor ��. Degree in Agricultural Engineering in 2002, Master ��. Degree in Food Technology in 2004 and PhD in Food Science and Technology in 2007. Prior to join to this university, he conducted over 8 years of postdoctoral research at McGill University (Canada), University of Saskatchewan (Canada), Agriculture and Agri-Food Canada (AAFC) and Cornell University (USA). During his study and postdoctoral research, he achieved a South Korean Government KRF (Korea Research Foundation) scholarship and a postdoctoral visiting fellowship under the Natural Science and Engineering Research Council (NSERC) of Canada. He received a PEPSICO 50 Emerging /exceptional early career professionals award from New York Academy of Science and PEPSICO in 2016. He is a University of Wisconsin- Stout Discovery Center Research Fellow for 2019-2020.

Teaching interests: FN 123-Science of Food, FN 244-Farm to Fork, FN 350 /550-Unit Operations in Food Processing, FN 450 /650 -Food Engineering, FN 465/665-Food Product Development, FN 728- Introduction to Food and Nutritional Sciences Research, FN 729-Research Proposal for Food and Nutritional Sciences, FN 735- Problems in Food Science and Nutrition, FN 746-Food Innovations, FN 750-Food Packaging and FN 770-Thesis-Food Science and Nutrition.

Research Interests: Extrusion in food processing, food engineering/processing/bioprocessing, drying of agricultural materials, thermal/non-thermal food processing, food and non-food product development and extraction and isolation of bioactive compounds.

He brought a strong diversified research background related to bio-product processing, food engineering and food processing, drying of agricultural materials, extruded food processing, dairy and snack product development and supercritical carbon dioxide extraction and isolation of functional compounds from plant materials, algae based Microbial Fuel Cell and protein-based food and non-food product development.

Professional Interests: He is a member of the Institute of Food Technologists (IFT, USA), the Association of Professional Engineers and Geoscientists in Saskatchewan (APEGS, Canada) and the International Association of Engineers (IAENG, Hong Kong). He is serving as editor for one journal, as editorial board member for 3 journals and as reviewer for almost all top ranked food science related journals. He served as external PhD thesis evaluator for foreign universities. He has been serving as member of Educational Activities Committee of University of Wisconsin-Stout since 2017.

Full Name: Dr. Pranabendu Mitra

Job Title: Associate Professor

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College: College of Arts & Human Sciences

Department: Kinesiology, Health, Food & Nutritional Sciences Department

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Degree: Ph.D. Food Science and Technology

University: Chungnam National University

Degree: M.S. Food Technology

University: Bangladesh Agricultural University

Degree: B.S. Agricultural Engineering

University: Bangladesh Agricultural University

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Cirrus Aircraft, Ashley Furniture benefit from engineering seniors’ R&D solutions

giffeyt — Wed, 18 Jun 2025 13:00:00 +0000

Cirrus Aircraft, Ashley Furniture benefit from engineering seniors’ R&D solutionsgiffeyt June 18, 2025

Capstone projects tackle mechanical, manufacturing challenges

Tom Giffey

After collectively putting thousands of hours into their capstone projects, the moment of truth arrived in May for seniors in University of Wisconsin-Stout ��. manufacturing engineering and mechanical engineering programs when they presented their projects to industry leaders, faculty and their peers.

The projects weren’t merely classroom exercises: For seniors in these undergraduate majors, the capstone projects involved creating working prototypes that addressed real-world challenges posed by corporate sponsors that included Cirrus Aircraft, 3M, Ashley Furniture, Nordson EDI, Realityworks, Industrial Heat Transfer and others.

These firms partner with students in �� . Robert F. Cervenka School of Engineering to address challenges as diverse as creating a system to pressure test heat exchangers to dispensing liquid silicon rubber into manufacturing equipment, and from safely stacking factory pallets to creating an automated system to chemically coat aluminum aircraft parts.

�� seniors discuss their capstone project on behalf of Cirrus Aircraft. The automated system behind them was designed to chemically coat machined aircraft parts.

Project called a ‘win-win’

That latter challenge, proposed by Duluth, Minnesota-based Cirrus Aircraft, was in the hard-working hands of a six-member team led in the spring semester by Gabrielle Winstead, a mechanical engineering major from Kennewick, Washington. The goal of the project was to create an automated system to chemically coat machined aircraft parts, which need to be dipped into – and removed from – nine successive tanks.

“It is super gratifying to know that what we worked on all year not only produced a successful working system but will possibly be implemented into a real company,” Winstead said.

Last fall, the student team visited the Cirrus facility to learn about the current manufacturing process, which involved an employee manually dipping the aircraft parts, a repetitive and time-consuming job.

Using the technical and communication skills they’ve gained throughout their �� careers, the capstone students got to work on a project that combined all three of the university ��. polytechnic tenets – applied learning and research, business and industry collaboration, and career-focused experiences. The team faced numerous challenges, from creating a machine that could properly move the parts up and down to procuring the right motors.

“We overcame the design challenges and procurement through a lot of brainstorming and prototyping,” said Winstead, who before graduation accepted a position as a field service engineer with Applied Materials in Boise, Idaho. “Additionally, seeking feedback from professors and other knowledgeable individuals was instrumental in refining our approach.”

In addition, size became an issue: There simply wasn’t enough space in the Manufacturing, Material Removal & Metal Forming Lab in Fryklund Hall to build an apparatus with nine full-sized tanks. Instead, the team created a prototype with just two tanks that demonstrated the process using automated, mechanical and pneumatic systems.

Metal parts are lifted from a tub of liquid in a demonstration of a machine developed by �� students in their engineering capstone course.

Antonio Meyer, a mechanical engineering major from Elk Mound who was team lead during the first semester, said consistent communication, real-time problem solving and adaptability were key to overcoming the problems the team encountered.

“I learned that strong teamwork relies on trust, clear communication and flexibility,” Meyer said. “Everyone has different working styles and strengths, and it ��. important to recognize and leverage those. I also learned the value of stepping up when the team needs direction but also stepping back and letting others take ownership of their parts.”

The students worked with Cirrus Manufacturing Engineering Manager Marc Wollak to provide project updates, ask questions and receive guidance.

Cirrus chose this engineering challenge because the current manual process required a technician ��. undivided attention, Wollak said. Automating the process would save a large amount of time for the operator.

“The final product was well done and provided a solid solution to our problem,” Wollak said. “There will always be modifications through continuous improvements, but the Cirrus team was very excited about the solution provided and the amount of detail that was captured for the process.”

Wollak added that working with �� was a valuable experience for both the students and Cirrus Aircraft. “Stout provides some amazing and talented students thorough their program and its win-win for both sides,” he said.

“The feedback from Cirrus was incredibly valuable,” agreed Meyer who is now a design engineer at Cretex Medical in Brooklyn Park, Minnesota. “They helped us stay grounded in real-world applications, offered insights we wouldn't have considered on our own, and kept our design aligned with their operational needs. It elevated the project from a student prototype to something with industrial relevance.”

The Cirrus capstone team also included mechanical engineering majors Tyler Geisenhoff of Chisago City, Minnesota; Nick Roller, of Antigo; and Carter Zaspel, of Gordon; and manufacturing engineering major Prena Rai of Nepal.

�� engineering students Luke Mertens, right, and Zachary Morgan demonstrate a wooden model of a machine they engineered for Ashley Furniture as part of their capstone course.

Students face a real-life heavy lift

During the spring semester, the Cirrus capstone group was just one of 14 teams composed of 80 students working on projects in various stages of developing in Fryklund Hall labs.

Among the first-semester capstone teams was one tackling a project on behalf of Arcadia-based Ashley Furniture. That team was tasked with designing a device that could lift and hold 6-foot-long, 100-pound pallets off the ground until a stack of 12 was collected. The biggest challenge was the requirement that they use electrical power, rather than pneumatics or hydraulics, to lift a heavy stack of pallets in one of the company ��. warehouses.

Luke Mertens, a double major in manufacturing and mechanical engineering from Easton, Minnesota, said his team overcame these challenges one at a time. “It all comes down to identifying what a functional need is of your design and then brainstorming potential design concepts that can satisfy that need,” he said. “This is a never-ending cycle. It is an unrelenting pursuit of solutions that are justifiable. A lot of it is mindset related. As a team, you must continuously tell yourselves there is a way to solve a given problem within the constraints you are operating in. Breakthroughs often come just after the moment you feel you’ve exhausted every option.”

The Ashley team also includes manufacturing engineering major Zachary Morgan of Eau Claire and mechanical engineering majors Chase Rodewald of Lake City, Minnesota, and Riley Stiehl of Alma.

The challenges that are inherent in the capstone process provided students with opportunities to learn, grow and adapt, Mertens explained. Along the way, he said, the team has been aided by input from representatives from Ashley as well as others who attended an end-of-semester presentation, which featured computer schematics and a small-scale model of what they will build in the fall semester.

“This feedback will be used to diagnose aspects of our design we need to further investigate, improve and validate,” Mertens said, adding he looks forward to presenting Ashley with a functional solution by the end of the year.

�� senior Gabrielle Winstead presents her team's capstone project.

Ready to step into industrial roles

The engineering capstone classes are led by Assistant Professor Dan Bee; Assistant Professor Nathan Spike, B.S. mechanical engineering program director; Senior Lecturer Glenn Bushendorf; Lecturer Anwr Al-Baghdadi; and Instrumentation Coordinator-Instructor Paul Craig, B.S. and M.S. manufacturing program director.

Bee said the faculty view themselves as facilitators in an open-ended process where the seniors must undertake their own research and develop their own solutions.

“We’re trying to give a real experience in a safe environment and help them be ready to step into a role like that in industry,” Bee said.

Students use a project management methodology called a “stage gate process,” which includes built-in reviews at key points. Students prepare a report at the end of the first semester, which is updated during the second semester. At that time the sponsor – typically an outside business – purchases the materials the team needs to build its prototype. After their final presentations, students submit what they’ve built and the accompanying documents to the companies for potential integration into manufacturing operations or continued development.

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�� seniors discuss their capstone project on behalf of Cirrus Aircraft. �� seniors discuss their capstone project on behalf of Cirrus Aircraft.

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Hero Caption: Luke Mertens, a double major in manufacturing and mechanical engineering, presents his capstone team's plans for a device to lift pallets for Ashley Furniture.

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