College of Engineering and Polymer Science

Date of Last Revision

2024-06-04 07:23:58


Mechanical Engineering

Honors Course

Honors Mechanical Engineering Senior Design 1 & 2

Number of Credits


Degree Name

Bachelor of Science

Date of Expected Graduation

Spring 2024


Schaeffler is launching a new assembly line for a battery in 2025. As part of the project, it is necessary to design and fabricate a reusable dunnage (packaging) specialized for the battery, meant for safe domestic transportation in the United States. Through an iterative process, the team developed a final dunnage design out of steel components that had a maximum footprint of 62 in X 43.5 in X 29.25 in and a weight of 821.682 lbs. The dunnage is stackable on itself up to two high, weighing a total of 4,918.724 lbs. when loaded with four batteries. The design was verified with Finite Element Analysis, which confirmed high strength and minimal stress and strain concentrations while under static loading. However, testing effectiveness during transportation remains uncertain, requiring additional testing for vibration and dynamic forces. Cost analysis was also performed with an estimate of $2,521.43 per dunnage, best made in quantities of six units.

Research Sponsor

Dr. Kai J. Kwon

First Reader

Dr. Gopal Nadkarni

Second Reader

Jonathan Rowe

Honors Faculty Advisor

Dr. Scott Sawyer

Proprietary and/or Confidential Information




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