Tag Archives: projects

Aluminum Castings

Steve Toth

Steve Toth,
Senior, Engineering Technology and Management

Athens, OH 4 November 2015

Ever since I took Metal Fabrication and Casting (ETM 2180) my sophomore year, I have been interested in castings. In the class, we were simply learning about the process. Now in my senior year, I’m delving deeper into the process.

One of the projects I have recently been working on is developing a casted aluminum OHIO badge using the sand casting process. My hopes behind this is to use the castings in my senior production run (capstone).


One thing that makes my development process different from traditional methods is that I have been developing and testing 3D printed patterns and runners which are traditionally machined or carved out. I started out with designing the badge using SolidWorks (a 3D drafting software). The part was then converted into a .STL file which could be read by the 3D printers owned by the ETM department.


Once the parts were printed, they were glued to the pattern board where sand could be packed around them. After the board is removed, a cavity is left for the molten aluminum to fill. As you can see, my first couple of patterns did not allow the sand to take.


After some massaging in the interior edges (larger fillets), larger draft angles and additional post print finishing I was able to create a workable pattern that was casted as seen in the picture at the top.

Now after creating a successful prototype and proving the concept, I have developed a (hopefully) ideal casting pattern that can be used in my capstone project next semester.

Internship at Electro Science Lab

Daron DiSabato

Daron DiSabato,
Senior, Electrical Engineering

Athens, OH 17 December 2013 – Over the past summer I completed an internship at the Ohio State University Electro Science Laboratory where I worked on a graduate level research project for the U.S. Navy. The project dealt with designing and building a code division multiple access (CDMA) cellular communication transceiver which was more power efficient, more cost effective, and had a smaller package size than current models in production.

The project was still in the early stages of design when I joined the team, and we began working on the analog front-end of the receiver. The first job I had was to run simulations of the circuitry in PSpice and AWR Microwave office to verify that the proposed designs would work before we purchased components and built the device. Over several weeks I was able to gain some great experience working with the software. We ran simulations using various different chips and circuit components. The ones that performed the best in simulation were the ones that we selected to be implemented in the design.

The second job I had during this project was to order the selected circuit components and build prototype breadboard circuits in the lab. I spent the next several weeks running various tests and fine-tuning the circuits to make sure they were performed to the expectations observed in the software simulations. After settling on the most optimum circuit design, my final job was to design the printed circuit boards that would be used in the actual device. This was the most difficult part of my interesting but also the most exciting. I used the industry standard PCB layout software, Cadence Allegro, and it had a very steep learning curve. Despite the challenge of learning the software, I was able to design two printed circuit boards for the device, which I have shown in the attached pictures.

PCB Design
PCB Design

Finally after four months since I completed the internship, they are finally printing the circuit boards I designed. I can’t wait to go back and see them in action spring semester!