Project Description
This project was a team-based manufacturing case study focused on reverse-engineering an SFF cooling tower nozzle with no prior design documentation. The objective was to identify the original material and manufacturing process, evaluate design trade-offs, and propose improved material and process alternatives. The project emphasized evidence-based reasoning, manufacturability, and decision-making in real-world engineering contexts.
Individual Contributions
Served as project manager, organizing meetings and task assignments
Led material identification and manufacturing process redesign sections
Developed trade-off tables and manufacturing process flow diagrams
Coordinated with instructor to review progress and ensure alignment with requirements
Submitted the project ahead of the due date
Solution Methods
Performed visual inspection and dimensional assessment of the component
Identified material using physical evidence and reference properties
Determined manufacturing process from surface features and geometry
Confirmed analysis and assumptions with the professor and TA during office hours
Proposed alternative materials and processes using trade-off analysis
Results
Produced a 19-page report containing 13 figures to give a comprehensive overview of our given part
Identified the most probable original material and manufacturing process
Developed a viable redesigned material and process alternative
Improved manufacturability while maintaining functional performance
Described through evidence based reasoning necessary manufacturing decisions
Completed the project ahead of schedule and met all documentation requirements
SFF Cooling Tower Nozzle: Materials & Manufacturing Case Study | Fall 2025
Top View of Part
Bottom View of Part
Side View of Part