Hexa-ceptional: George Mason systems and industrial engineering team wins big for building smart

Nathan Kahl — Mon, 12 May 2025 17:52:29 +0000

Hexa-ceptional: George Mason systems and industrial engineering team wins big for building smart Nathan Kahl Mon, 05/12/2025 - 13:52

In This Story

John Shortle

Lance Sherry

A George Mason 麻豆国产 systems and industrial engineering (SIE) capstone team won second place and $2,000 in the General Entrepreneurship track of the Patriot Pitch competition and won Best Presentation in the General Engineering category at the prestigious General Donald R. Keith Memorial Conference at West Point.聽

The NOVAFoam team at Patriot Pitch. Photo by John Boal Photography

The SIE capstone team set out to determine the practicality of the Hexayurt, a rugged, hexagon-shaped structure made from flat, triangular panels that can be quickly assembled in areas hit with natural disasters. Hexayurts provide urgently needed temporary shelters for food storage, food preparation, healthcare services, and living spaces. The team started with a process of 鈥渃ustomer discovery.鈥澛�聽

鈥淚n conducting stakeholder interviews, it emerged there were several issues with these shelters,鈥� said SIE student Ethan Ford, team lead for the capstone project. 鈥淔irst, transporting the materials can be expensive especially when the location is remote, or roads are no longer functional. Next, the shelters need to provide insulation from the cold or heat and be impermeable to prevent soaking up water and growing mold. Finally, it would be nice if the materials used to build the shelters had anti-bacterial properties.鈥�聽

The team identified a synthetic lumber, known as Novafoam, as a potential improved material for the shelters. The lumber is manufactured by an extrusion process developed by Italian inventor Mario Gualco and project sponsor Julia Rotta.聽

鈥淭he synthetic lumber is lightweight significantly reducing transportation costs,鈥� said Stephano Barra, a team member. 鈥淚t also has excellent insulation properties. It is impermeable and anti-bacterial.鈥�聽

Hexayurts deployed in the desert. Photo credit Wikimedia Commons.聽

鈥淚n addition to the material properties, the Novafoam is made from recycled Styrofoam,鈥� said team member Mickhail Ivanov. 鈥淏y recycling the Styrofoam, we are reducing the load on landfills for non-biodegradable materials.鈥�聽

The team documented all the stages of production from raw materials supply to pallets of finished synthetic lumber, focusing on the time-and-motion in production and the impact of fluctuations in the process. To better understand production bottlenecks, the team studied The Goal by Eli Goldratt鈥攁 classic text in operations and systems thinking. 鈥淚t gave us a new perspective on balancing flow and throughput,鈥� said team member Michael Smith.聽聽

The team also developed a detailed simulation model of the entire supply chain and production process, which 鈥渨as instrumental in the design of the factory,鈥� said team member Trevor Geisler. 鈥淭he team spent hours adjusting the number and location of machines, and their parameters, to balance the flow and maximize the throughput. The final design could produce enough synthetic lumber for 2000 Hexayurts in less than 30 days.鈥澛�聽

Team member Ethan Ford added, 鈥淭he simulation model was also critically important for calculating the operating costs of the plant and the final cost of production for the lumber.鈥�聽

鈥淭his project is a great example of how systems and industrial engineering can improve lives鈥攅specially in crisis situations,鈥� said John Shortle, Systems Engineering and Operations Research department chair. 鈥淲e're proud of what this team accomplished.鈥�聽

Topics

Systems Engineering and Operations Research

materials

Patriot Pitch Competition

Students

Students win contests designing delivery drones that respond to real-time wind change

Nathan Kahl — Wed, 08 May 2024 13:09:04 +0000

Students win contests designing delivery drones that respond to real-time wind change Nathan Kahl Wed, 05/08/2024 - 09:09

Part of the charm of tiny Tangier Island, located smack dab in the middle of the Chesapeake Bay, is that in some ways it seems stuck in time, with residents speaking an outdated dialect and relying on crabbing for a living. What isn鈥檛 so endearing to residents about their simple life is the need to take a ferry to the Eastern Shore to obtain necessities, such prescription medications. Such a trip is an all-day affair, often causing people to miss work and lose wages.

But now Riverside Health System and DroneUp, a delivery service based in Virginia Beach, are working with a team of George Mason 麻豆国产 students to deliver medications via a small drone. But even that poses challenges.

鈥淎s a part of my systems engineering senior design project, my team and I performed a context analysis and a stakeholder analysis to find the performance gaps for a case study about drone delivery to an island located in the Chesapeake Bay鈥揟angier Island,鈥� said senior Diana Machuca, who is majoring in systems and industrial engineering. 鈥淭o bridge the gaps, we designed the Drone Range Dynamic System and came up with a business plan for the project.鈥�聽

鈥淭he route is 15 nautical miles (NM) from Onley, Virginia, to Tangier Island,鈥� said team member Darius Jack. 鈥淭he route traverses both land and terrain resulting in significant wind shifts, including onshore and offshore winds, depending on the time of day.鈥�

Depending on a drone鈥檚 design, it can be very sensitive to wind, requiring extensive analysis. Team member Grean Ramos said, 鈥淲e developed an aerodynamic simulation of the drone and its batteries. The simulation showed that the 15 NM route is close to the drone's range limit. Any unexpected headwind could result in the drone running out of battery and needing to land before reaching Tangier Island.鈥�

鈥淭here are weather stations at Onley and at Tangier Island airports, but no weather stations in-between," said team member Diana Machuca. "We analyzed one year of hourly wind data from the airports and found that headwinds would prevent the drone from reaching the clinic 32 percent of the time.鈥�

Team members Gurkirt Tahim, Darius Jack, Grean Ramon, and Diana Machuca

So the team developed a Drone Range Decision-support System (DRDS). The DRDS uses the aerodynamic simulation described above to continuously monitor the range-remaining as the drone flies. If the simulation estimates that the drone has experienced an unexpected wind and will no longer have enough battery power to reach the destination, it recommends the drone operator to return home (if it can) or to land safely in designated landing zones. Simulations showed winds would require the drone to return home 17 percent of the time.

The team鈥檚 plan won First Place in the STEM Track in the Patriot Pitch Competition, a annual contest sponsored by the Costello College of Business at George Mason, and First Place in the Systems and Analytics Track at the Sage Memorial Design Competition, a student-focused international forum for the design of complex systems.

鈥淲orking on this project was an amazing experience,鈥� said Jack. 鈥淲e had to use all the system engineering knowledge and skills we learned over the past three years. Building systems in the real-world is hard, but perseverance and creativity pay off.鈥�

Topics

Drones

Systems Engineering and Operations Research

aeronautics

Patriot Pitch Competition

entrepreneurship

Students