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The project addresses instability in the dissolution of tantalum (Ta) anodes in hydrofluoric acid (HF), where hydrogen gas generated during the reaction becomes trapped in the solution, forming foam that disrupts the process and creates safety risks. Using the PRIZ Platform, a Functional Model of the system was developed. The model revealed that the HF solution is both the most functional and the most problematic component, leading to a physical contradiction: HF must interact with Ta anodes to enable dissolution, but must not retain the hydrogen gas produced during the reaction. Applying the PRIZ principle of Separation in Space, two reactor concepts were proposed: a spray interaction reactor, where HF is pumped to spray onto anodes placed above the solution, and a surface wetting reactor, where anodes are positioned at the top of the solution, allowing natural circulation and easy hydrogen release. Both designs eliminate foam formation and provide a stable, controllable, and safer dissolution process.

Semiconductor devices are becoming more complex and expensive. But what exactly are we paying for when we buy a computer, cellphone, or any device containing a microchip? It’s not for radically new functions—the core components remain the same: transistors and interconnections. According to Moore’s law, transistors are getting smaller, with more interconnection layers added, making the manufacturing process longer and more costly. In reality, we’re paying for the inability of engineers to efficiently solve engineering challenges. This project leverages System Functional Modeling (SFM) to analyze the IC interconnection layer and Process Functional Modeling (PFM) to evaluate its manufacturing process. These analyses aim to deepen our understanding of both the device and the production process, generating innovative solutions for cost reduction and improved efficiency.

To reduce high turnover at the plant the managers propose different ideas, but it does not help. All proposed solutions are good, but there are some of them that are blocking the effectiveness of the rest of the solutions. The purpose of the project is to analyze the proposed solutions (perceptions) and define the blocked. The solutions with high blocking rank should be completed first to ensure the effectiveness of the rest of the ideas. The Perception Mapping (PMap) creative thinking tool was used for the blockers definition.

Who is the most important at a manufacturing plant? Do you believe that management is the most important? We created a Functional Model of a typical manufacturing and revealed that Process Engineers are the most functional. So, if you want your production to be successful, invest in process engineers first.

The integration of CFRP materials into automotive designs presents challenges related to compatibility, performance, and safety, necessitating a careful transition from a Chromolly tubular space frame to a CFRP monocoque. Key considerations include determining the optimal geometry for suspension, aerodynamic features, and the placement of components like the battery pack and sensors, all while adhering to FSAE safety protocols. Additionally, decisions regarding the production method—whether to use preimpregnated carbon fibers or an injection method—must be made early to facilitate timely production. The development process involves creating molds and plugs from suitable materials, ensuring that all assemblies can be connected without compromising structural integrity, and maintaining strict adherence to budget constraints and sourcing of materials.