Steam Engine Design and Fabrication

Project Overview:
In this hands-on engineering project, my team and I designed and built a functional steam engine, focusing on system integration, material selection, and iterative problem-solving. The project was divided into key components: the piston and chamber, the flywheel, the flywheel stands, and the base. My primary responsibility was designing and constructing the base, ensuring structural integrity, heat resistance, and adaptability to design changes.

Problem & Design Challenges:
Steam engines operate under high-temperature and pressure conditions, making material selection and precision engineering critical. Key challenges included:

Achieving a functional piston seal while minimizing friction.
Selecting a durable and heat-resistant base material to withstand engine vibrations and high temperatures.
Iteratively improving the flywheel design to enhance system efficiency.

Engineering Solutions & Contributions:
Base Design & Adaptation: To balance durability and flexibility, we initially considered aluminum but opted for wood with heat-resistant treatment (rated up to 2000°F). This choice allowed for quick modifications as the engine evolved.
Flywheel Optimization: After early performance issues, we increased the flywheel’s size and weight, switching from aluminum to a ½-inch steel design for improved rotational inertia.
Piston Sealing & Friction Reduction: We explored multiple iterations, from sand-casted pistons to 3D-printed designs with integrated O-rings, ultimately improving the seal and reducing energy losses.
Manufacturing & Prototyping Techniques: This project provided hands-on experience with waterjet cutting, sand casting, drill presses, and metal fabrication in Tufts’ Bray Lab.

Outcome & Impact:
While the final engine required additional refinements to achieve full operational efficiency, the project strengthened my engineering problem-solving skills, collaboration, and iterative design process. By integrating real-world constraints into the design, I gained valuable experience in product development, mechanical systems, and usability testing, skills that align with my passion for human-centered engineering in fields like medical technology, sports, and automotive design.

Reflection:
This project was an invaluable learning experience in iterative design, hands-on engineering, and effective team communication. One of the biggest takeaways was the importance of flexibility in design, many of our initial ideas had to be revised based on real-world constraints. Additionally, I gained a deeper appreciation for material selection and manufacturing techniques, as small design changes often had significant downstream effects on performance. I plan to apply these lessons to future projects in usability research, interaction design, and product development, ensuring that user needs and engineering constraints are seamlessly integrated into the design process.