I-MECH
REJUVENATING POTENTIALS
Department of
Mechanical engineering
SOT. PDEU
MECH-A-THON
MECH-A-THON
A-WEEK LONG
MECHANICAL
HACKATHON
Design and Manufacturing Thermal and Fluids
Robotics and IoT And Many More...
For further information DM on imech_pdeu
TABLE OF CONTENTS
1. Assistive Robotic Gripper for Limited Hand Mobility
2 Posture Correction Wearable for Students
3. Water Purification Using Nanofilters
4. Optimized Structural Design of an Aircraft Wing
Spar for Weight Reduction and Strength
Enhancement
5. Optimized Design of 3D-Printed Heat-Resistant
Turbine Blades for Power Plants
6. CFD Simulation for Pipeline Flow Optimization
Using Sulfuric Acid in Chemical Processing
Pipelines
7. Smart Cooling System for EV Batteries
8. Electricity Generation from Slow-Moving
Canals
9. Structural Design and Optimization of a
CubeSat Frame for LEO
10. Design and Optimization of a Foldable Drone Frame
for Compact Transportation and Efficient Deployment
11. Passive Cooling System for Small Rooms
12. Soil Nutrient Measuring Device and Crop
Suggestion System
2
1. Assistive Robotic Gripper for Limited Hand Mobility
Introduction
Many individuals with limited hand mobility struggle with everyday tasks like
holding a cup or gripping a pen. Existing assistive devices are often bulky,
expensive, or difficult to use. There is a need for a simple, affordable, and
effective robotic gripper that can help individuals regain independence in
daily activities.
Problem Statement
The objective is to design a lightweight, ergonomic, and cost-effective
robotic gripper that aids individuals with limited hand mobility in performing
essential gripping actions. The mechanism should be easy to operate,
requiring minimal force while ensuring a firm yet gentle hold on everyday
objects. It should integrate seamlessly with the user’s hand, feature an
adaptive grip for various object shapes and sizes, and prioritize comfort,
durability, and affordability.
Students Are Required To:
Develop a CAD model of the robotic gripper, ensuring an ergonomic and
compact design.
Simulate gripping actions using software to analyze grip strength,
adaptability, and pressure distribution.
Evaluate different gripping mechanisms (e.g., soft robotics, linkage-
based, or motorized) for optimal performance.
Test material options (such as silicone, PLA, or lightweight metals) to
balance durability and affordability.
Optimize the control mechanism by selecting between manual, semi-
automatic, or sensor-based activation methods.
Enhance safety and comfort by designing padding, force control, and
skin-friendly contact surfaces.
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Design Considerations:
Ease of use – Minimal dexterity required for operation.
Add-on design – Should integrate with the user’s hand rather than being
a full prosthetic.
Adaptive grip – Should securely hold objects of different shapes and sizes.
Lightweight and portable – Ensures daily usability.
Operation method – Manual or semi-automatic, avoiding excessive
complexity.
Durability and manufacturability – Made from cost-effective materials.
Safety and comfort – Prevents strain or discomfort.
Extra features like force sensors or smart controls will be rewarded.
What We Expect from Teams:
A detailed CAD model of the proposed mechanism.
A working simulation (if applicable) demonstrating grip strength and
adaptability.
A report covering design choices, material selection, and cost analysis.
A short presentation explaining functionality and innovation.
4
2. Posture Correction Wearable for Students
Introduction
Poor posture is a common issue among students, leading to long-term health
problems. Traditional solutions like braces can be uncomfortable and
restrictive. A smart, wearable device that detects bad posture and provides
real-time feedback can help students develop better sitting habits.
Problem Statement
The objective is to design a compact, lightweight, and wearable posture
correction device that detects and alerts students when they slouch while
studying. The device should provide real-time feedback through vibration,
sound, or visual indicators, ensuring ease of use, comfort for long durations,
and affordability. It should be adjustable to different users, energy-efficient,
and non-intrusive, promoting better posture habits without restricting
movement.
Design Considerations:
Comfort & lightweight – Should be wearable for long durations.
Real-time posture detection – Alerts (vibration, sound, or LED indicator)
upon slouching.
Adjustability – Adaptable to different users and study environments.
Non-intrusive design – Should not restrict movement.
Power efficiency – Optimized battery life.
Simple operation – Minimal user input required.
Affordability – Cost-effective alternative to existing solutions.
Additional features like data tracking or app connectivity will be rewarded.
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Students Are Required To:
Develop a CAD model of the wearable, ensuring ergonomic and compact
design.
Implement real-time posture detection using sensors (e.g., IMU, flex
sensors).
Simulate feedback mechanisms (e.g., vibration, sound, or LED alerts) and
evaluate their effectiveness.
Optimize adjustability to ensure the device suits different users and study
environments.
Test power efficiency by selecting appropriate battery and power
management systems.
Enhance usability by designing a simple and intuitive control interface.
Compare affordability by analyzing manufacturing costs and comparing
with existing solutions.
What We Expect from Teams:
A prototype design (physical model or CAD).
A report detailing the working mechanism, material selection, and cost.
A short presentation explaining how the device functions.
An economic analysis comparing this solution with existing products.
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3. Water Purification Using Nanofilters
Introduction
Access to clean drinking water is a global challenge. Many filtration
methods are expensive, inefficient, or difficult to maintain. Nanomaterials
have shown promise in filtering out heavy metals and bacteria at a lower
cost. A low-cost, efficient nanofilter-based water purification system could
provide safe drinking water for communities with poor water quality.
Problem Statement
The objective is to design a low-cost, nanomaterial-based water
purification system that efficiently removes heavy metals and bacteria
from drinking water. The system should be scalable for both household
and community use, easy to maintain with minimal technical expertise,
and cost-effective to ensure accessibility in low-income or rural areas.
Design Considerations:
Effective filtration – Should remove heavy metals (lead, arsenic,
mercury) and bacteria.
Affordability & accessibility – Suitable for rural/low-income areas.
Ease of use – Simple operation with minimal technical skills required.
Sustainability – Should use environmentally friendly materials.
Scalability – Adaptable for household and community-level use.
Portability – If designed for personal use, it should be compact and
mobile.
Low maintenance – Long-lasting filtration capability.
Additional innovations, such as self-cleaning mechanisms, will be
rewarded.
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Students Are Required To:
Develop a CAD model or physical prototype demonstrating the filtration
mechanism.
Test and simulate filtration efficiency for removing heavy metals and
bacteria.
Optimize affordability and accessibility to ensure suitability for low-income
and rural areas.
Enhance ease of use by designing a simple, user-friendly system requiring
minimal technical skills.
Evaluate sustainability by selecting eco-friendly materials and filtration
techniques.
Ensure scalability for both household and community-level applications.
Analyze portability if designed for personal use, ensuring a compact and
mobile solution.
Assess long-term durability and maintenance for prolonged usage with
minimal upkeep.
What We Expect from Teams:
A physical prototype or CAD model demonstrating the filtration
mechanism.
A report detailing material choice, efficiency, and cost analysis.
A simulation (if applicable) showcasing the effectiveness of filtration.
A short presentation explaining the system’s working and feasibility.
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4. Optimized Structural Design of an Aircraft Wing
Spar for Weight Reduction and Strength
Enhancement
Introduction
The wing spar is the primary structural component of an aircraft wing,
ensuring strength, rigidity, and resistance to aerodynamic loads. Traditional
designs, though effective, often carry excess weight. By leveraging topology
optimization, CAD modeling, and FEA simulations, a more efficient spar
design can be developed to enhance fuel efficiency, reduce structural
weight, and maintain strength.
Problem Statement
The objective is to redesign an aircraft wing spar to achieve a superior
strength-to-weight ratio while ensuring aerodynamic efficiency and
manufacturability. The new design should optimize material distribution to
minimize stress concentrations, incorporate hollow, ribbed, or truss-based
reinforcements to reduce weight, and enhance fatigue resistance to extend
the structure’s lifespan.
Students Are Required To:
Conduct FEA simulations to analyze stress distribution in a conventional
wing spar.
Redesign the spar using CAD tools to optimize weight and load-bearing
efficiency.
Compare the optimized design with traditional spar designs in terms of
weight savings, stress endurance, and manufacturability.
9
Design Considerations:
Load Distribution & Structural Integrity – Must effectively withstand
aerodynamic forces without excessive deformation.
Topology Optimization – Reduce unnecessary material while maintaining
structural strength.
Cross-Sectional Geometry – Compare I-beam, box-beam, honeycomb,
and truss-like structures for optimal strength-to-weight ratio.
Fatigue & Stress Analysis – Evaluate stress concentration points and crack
propagation under repeated flight cycles.
Aerodynamic Efficiency – Ensure the design does not negatively impact
airflow or increase drag.
Manufacturability & Cost Efficiency – Should be feasible for production
using additive manufacturing or CNC machining.
What We Expect from Teams:
A CAD model of the optimized wing spar.
FEA simulations demonstrating stress distribution and weight reduction.
A comparative study of the optimized design versus conventional spars.
A short presentation explaining the design process, material selection, and
feasibility.
10
5. Optimized Design of 3D-Printed Heat-Resistant
Turbine Blades for Power Plants
Introduction
Turbine blades in power plants operate under extreme temperatures and
high mechanical stresses, leading to thermal expansion, fatigue, and creep
deformation. Traditional nickel-based superalloys are widely used, but 3D
printing with composite materials (e.g., ceramic-matrix composites (CMCs))
offers the potential for better heat resistance, reduced weight, and improved
efficiency.
Problem Statement
The objective is to design and optimize a 3D-printed turbine blade using
heat-resistant composite materials to enhance cooling efficiency and
mechanical durability. The design should incorporate internal cooling
channels or lattice structures to improve heat dissipation while ensuring the
blade withstands high thermal and mechanical loads without
compromising structural integrity. Additionally, the blade must be
compatible with advanced additive manufacturing techniques such as
Selective Laser Melting (SLM) or Direct Energy Deposition (DED) to enable
efficient and scalable production.
Students Are Required To:
Analyze thermal and mechanical stresses in conventional turbine blades.
Redesign the blade using CAD to integrate cooling mechanisms and
optimized geometries.
Select an optimal composite material (e.g., SiC-based CMCs, hybrid
metal-ceramic materials) and justify its use.
Assess 3D printing feasibility and recommend an appropriate
manufacturing method.
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Design Considerations:
Heat Resistance & Thermal Expansion – The material must withstand
above 1200°C without excessive deformation.
Internal Cooling Mechanisms – Implement hollow cooling channels or
lattice structures for better heat dissipation.
Mechanical Durability – Ensure resistance to centrifugal forces, fatigue,
and oxidation.
Manufacturability – The design should be suitable for 3D printing,
requiring minimal post-processing.
Efficiency & Performance Enhancement – The optimized blade should
improve fuel efficiency and energy output.
What We Expect from Teams:
A detailed CAD model of the optimized turbine blade.
FEA and CFD simulations to analyze thermal and mechanical
performance.
A comparison of materials and manufacturing feasibility.
A short presentation explaining design choices, advantages, and
challenges
12
6. CFD Simulation for Pipeline Flow Optimization
Using Sulfuric Acid in Chemical Processing Pipelines
Introduction:
Pipelines in the chemical industry transport highly corrosive fluids, which lead
to pipe degradation, turbulence-induced wear, and pressure losses over
time. Sulfuric acid (H₂SO₄) is one of the most widely used industrial
chemicals, found in applications such as petroleum refining, fertilizer
production, and battery manufacturing. However, its high reactivity with steel
and iron pipelines results in corrosion, erosion, and structural weakening over
time.
By optimizing fluid flow dynamics using Computational Fluid Dynamics (CFD)
simulations, engineers can minimize turbulence, reduce pressure losses, and
enhance the lifespan of pipelines.
Problem Statement:
Students must simulate the flow of sulfuric acid (H₂SO₄) in a steel pipeline
using CFD software and propose design modifications to:
Reduce turbulence and pressure loss.
Minimize material degradation due to erosion and corrosion.
Optimize pipeline geometry for improved flow stability.
Design Considerations
Fluid Behavior & Corrosiveness – Analyze sulfuric acid’s interaction with
steel, considering concentration, temperature, and Reynolds number.
Turbulence Reduction & Flow Optimization – Optimize pipe curvature,
roughness, and junctions to minimize turbulence, eddies, and mechanical
stress.
Pressure Drop & Energy Efficiency – Evaluate velocity profiles, turbulence,
and pressure drop to reduce energy consumption.
Corrosion & Erosion Resistance – Compare protective coatings (e.g.,
polymer, epoxy, ceramic) and explore corrosion-resistant materials (e.g.,
PTFE, stainless steel, composites).
Industrial Feasibility & Compliance – Ensure cost-effective, scalable
designs that meet chemical industry safety standards.
13
Students are required to:
Simulate the flow of sulfuric acid (H₂SO₄) in a steel pipeline using CFD
software to analyze velocity profiles, turbulence intensity, and pressure
drop.
Evaluate the effect of pipeline geometry (e.g., bends, junctions, or
diameter variations) on flow stability and erosion rates.
Redesign the pipeline configuration by incorporating smooth transitions,
optimized bend angles, or internal coatings to reduce turbulence and
corrosion.
Compare different protective coatings (such as polymer liners, epoxy
coatings, or ceramic coatings) and assess their effectiveness in
minimizing corrosion and erosion damage.
What We Expect from Teams
CFD Simulation & Analysis – A detailed simulation of sulfuric acid flow,
showcasing turbulence levels, pressure drop, and erosion zones.
Pipeline Design Modifications – Optimized geometry for reduced
turbulence and improved efficiency.
Comparative Study – Evaluation of different pipeline coatings and
materials.
Technical Report – Covering simulation results, design choices, and
industrial feasibility.
Presentation – A short video or slideshow explaining findings and
proposed improvements.
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7. Smart Cooling System for EV Batteries
Introduction
Electric vehicles (EVs) rely heavily on battery packs for power, but
excessive heat generation during operation affects battery performance,
efficiency, and lifespan. Effective thermal management is crucial to
maintain optimal battery temperature, prevent overheating, and extend
battery life. A liquid cooling system offers a promising solution by
efficiently transferring heat away from the battery cells. Designing a
smart cooling system with optimized fluid flow and thermal control is
essential for improving EV battery performance and safety.
Problem Statement
Design and simulate a liquid cooling system for electric vehicle battery
packs to maintain optimal operating temperature, prevent overheating,
and extend battery life. The system should ensure uniform cooling,
minimize power consumption, and be practical for integration into
existing battery modules.
Design Considerations:
Effective heat dissipation – Design channels or plates to ensure
uniform cooling across battery cells.
Low power consumption – Optimize pump and coolant usage to
minimize energy consumption.
Compact design – Ensure the cooling system fits within the battery
pack enclosure without increasing overall size.
Lightweight materials – Use materials that do not significantly
increase vehicle weight.
Thermal stability – Maintain battery temperature within the optimal
range under various operating conditions.
Ease of manufacturing – Design should be feasible for large-scale
manufacturing.
Coolant selection – Choose a non-corrosive, efficient coolant that
maximizes heat transfer.
Cost-effectiveness – Balance performance with affordable design
and material choices. 15
What We Expect from Teams:
A detailed CAD model of the liquid cooling system integrated with the
battery pack.
A thermal simulation using software like ANSYS, Simulink, or COMSOL
demonstrating heat dissipation.
A report covering design approach, material selection, coolant choice,
and thermal performance.
A presentation explaining the working principle, simulation results, and
potential application in EVs.
16
8. Electricity Generation from Slow-Moving Canals
Introduction
Water bodies, including canals and slow-moving rivers, cover a
significant part of the Earth’s surface and hold untapped potential for
renewable energy. While traditional hydropower systems rely on dams or
turbines, emerging technologies use vortex-induced vibrations to
generate clean energy from slow-moving water. This offers an affordable
and sustainable alternative for rural electrification, street lighting, and
self-sustaining communities.
Problem Statement
Design a simple, cost-effective, and efficient mechanism to harness
electricity from slow-moving canals or rivers. The system should be easy
to install, maintain, and scalable for practical applications.
Design Considerations:
Simple mechanism – Should not require complex turbines or dams.
Ease of installation – Can be deployed in existing canal systems.
Cost-effective – Affordable materials and minimal maintenance.
Energy efficiency – Maximizes power output from slow-moving water.
Structural durability – Withstands continuous water flow and
environmental factors.
Scalability – Adaptable for small-scale and larger applications.
Sustainability – Uses eco-friendly materials and minimizes
environmental impact.
Additional features such as energy storage or grid integration will be
rewarded.
What We Expect from Teams:
A conceptual design or CAD model of the mechanism.
A report explaining the working principle, materials, and feasibility.
A simulation or performance analysis (if applicable).
A short presentation detailing innovation, cost-effectiveness, and
scalability.
17
9. Structural Design and Optimization of a CubeSat
Frame for LEO
Introduction
CubeSats are miniaturized satellites used for space research, technology
demonstrations, and educational purposes. Their compact size,
modularity, and cost-effectiveness make them ideal for low Earth orbit
(LEO) missions. However, designing a lightweight, structurally robust, and
thermally stable CubeSat frame is crucial for ensuring mission success
while withstanding launch loads, space conditions, and payload
requirements.
Problem Statement
Design and develop a structurally optimized CubeSat frame that meets
standard CubeSat dimensions (10 cm x 10 cm x 10 cm for 1U). The frame
should be lightweight, durable, and capable of withstanding launch
forces and space conditions while maximizing internal space for payload
integration.
Design Considerations:
Structural Integrity & Lightweight Materials – Designed to withstand
launch loads, vibrations, and space radiation.
Compact & Modular Design - Conform to CubeSat standard
dimensions (1U, expandable to 3U, 6U, etc.).
Thermal Management - Effective heat dissipation to prevent
overheating.
Manufacturing & Cost Efficiency – Design should be easily
manufacturable using CNC machining, 3D printing, or sheet metal
fabrication.
Payload & Component Integration – Ensure frame allows easy
mounting of subsystems (power, communication, payload, sensors).
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What We Expect from Teams:
A detailed CAD model of the proposed mechanism.
Structural Analysis (if applicable) – Simulation demonstrating
mechanical strength and durability.
A report covering design choices, material selection, and cost
analysis.
Prototype Demonstration (if possible) – A scaled or full-size model
showcasing the design.
A short presentation explaining functionality and innovation.
19
10. Design and Optimization of a Foldable Drone
Frame for Compact Transportation and Efficient
Deployment
Introduction
Conventional drone frames are often rigid and bulky, making
transportation and storage challenging. This limits the drone's
practicality, especially for outdoor operations like surveillance, delivery
services, and aerial photography. A foldable drone frame can address
this issue by reducing the overall size during transport while maintaining
stability and performance during flight.
Problem Statement
Design a foldable drone frame that minimizes space consumption during
transportation without compromising the drone’s flight performance. The
frame should be lightweight, durable, and easy to assemble and
disassemble. It should also accommodate standard drone components
and ensure quick deployment.
Design Considerations:
Compact folding mechanism – Should significantly reduce the
drone’s size when not in use.
Structural stability – Must maintain flight performance after repeated
folding and unfolding.
Lightweight and durable materials – Ensures easy transportation and
prolonged usability.
Ease of assembly – Quick setup without technical complications.
Compatibility with standard components – Should fit motors,
propellers, and flight controllers.
Cost-effective design – Ensure affordability and practical
manufacturing.
User-friendly operation – Simple unfolding and deployment process.
Impact resistance – Should withstand minor impacts or vibrations during
flight.
20
What We Expect from Teams:
A detailed CAD model of the foldable drone frame.
A working simulation (if applicable) demonstrating folding and
unfolding.
A report covering design choices, material selection, and cost
analysis.
A video presentation explaining the folding mechanism and assembly
process.
21
11. Passive Cooling System for Small Rooms
Introduction
In hot and humid regions, cooling small rooms without electricity is a
challenge. Passive cooling systems can reduce indoor temperatures
without active energy consumption.
Problem Statement
Design a passive cooling system (such as heat chimneys, evaporative
coolers, or venturi-based cooling) for small residential rooms. The system
should reduce indoor temperature using natural airflow or evaporative
cooling.
Design Considerations:
Use of low-cost materials.
Simple and easy installation.
Effective heat dissipation.
Low maintenance.
What We Expect from Teams:
CAD model of the cooling system.
Heat transfer analysis or airflow simulation.
Brief report explaining the design, material cost, and cooling
efficiency.
22
12. Soil Nutrient Measuring Device and Crop
Suggestion System
Introduction
Farmers often face challenges in determining the nutrient content of their
soil, leading to poor crop yields or excessive use of fertilizers. A compact,
portable device that can quickly measure soil nutrients and recommend the
most suitable crops can significantly improve agricultural productivity. This
device would promote optimized fertilizer usage and higher yield through
informed crop selection.
Problem Statement
Design a portable soil nutrient measuring device that can quickly analyze soil
parameters (such as nitrogen, phosphorus, potassium, and pH levels) and
suggest suitable crops based on the nutrient content. The device should
provide easy-to-understand recommendations, minimizing the need for
laboratory soil tests.
Design Considerations:
Sensor integration – Use sensors to measure NPK (Nitrogen, Phosphorus,
Potassium) and soil pH.
Crop recommendation algorithm – Based on the measured values,
recommend the most suitable crops using a predefined database or
logic.
Portability – The device should be lightweight, handheld, and battery-
powered.
Ease of use – Provide output in simple, easy-to-understand language
(like "Best crop: Wheat, Rice").
Low-cost design – Use affordable sensors and microcontrollers to keep
the overall device cost low.
Optional IoT feature (Bonus) – Connect the device to a mobile app or
cloud storage for data logging and analysis over time.
What We Expect from Teams:
CAD model of the device casing and internal structure.
Circuit diagram for sensor and microcontroller connections.
Basic working code for measuring soil parameters and suggesting crops.
Test report with a few soil samples to validate the device’s accuracy.
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Cost analysis for components and estimated device cost.
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Thank You
MECH-A-THON ’25