Engineering Senior Design Projects

Engineering Senior Design Projects

The Engineering senior design project is a two-semester effort jointly supervised by St. Mary’s faculty and engineers from the sponsoring organization. Seniors work on solving open-ended problems submitted by and relevant to our industrial collaborators.

The senior project culminates the professional education received at St. Mary’s. Each project is a comprehensive effort: working in conjunction with an industrial internship, the students must apply their educational experience and expertise to identify, plan and design a practical solution to an actual problem.

The end product is a professional report and presentations given before students, faculty, industrial panelists and the sponsoring organization. Interdisciplinary teamwork among students is encouraged through the application of concepts, skills and knowledge acquired in the classroom.

Previous Sponsors

Senior design projects have been sponsored by organizations such as:

2025 Projects

• Lean Six Sigma Assessment of Level of Care Decision-Making at the Audie L. Murphy VA Hospital

  Team: Sebastian Gonzalez Vilcarromero (IE), Roberto Abarca (EM), Arturo Arana (EM)

  Sponsor: Audie L. Murphy VA Hospital

  The senior design project was conducted as an industrial internship at Audie L. Murphy VA Hospital. Its aims were to improve compliance with Supporting Indicator (SI) Utilization Management (UM) National Utilization Management Integration (NUMI) reviews.

  We addressed a significant performance gap, with only 51% of admissions meeting the Level of Care (LOC) standards, compared to the 75% national benchmark. This gap has led to inefficiencies and inappropriate treatment assignments. The primary goal was to increase compliance to 75%.

  Running from August 2024 to April 2025, the project followed the DMAIC methodology to systematically improve the admission review process. Deliverables include phase reports, standardized documentation, process maps, training materials and a final report. Improvements will focus on Utilization Management and the NUMI system, using InterQual for standardized admission decisions. The scope excludes initial reviews and outpatient services.

  The objective of the project was to find the appropriate level of care of admissions in the Audie L. Murphy hospital and secure the patients to meet criteria for where they are admitted. The project design was guided by DMAIC (Define, Measure, Analyze, Improve and Control) principles. Throughout the project, we collected data to support this research effort and evaluate the effectiveness of the solutions.

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• A Lean Six Sigma Approach to Compliance of the F9-F11 Panic System at the San Antonio VA Hospital

  Team: Otoniel Gonzalez de Leon Perez (IE), Mariano Pardo (EM) and Adrian Roda (EM)

  Sponsor: Audie L. Murphy VA Hospital

  VA Hospital employees are at risk of encountering a distress situation as they fulfill their daily functions at the facility. As part of their commitment to protect their employees daily, the San Antonio VA Hospital implemented a safety program called F9-F11. The program is a distress signal system that allows the employees to request police assistance whenever they feel threatened by a patient by simultaneously pressing the F9 and F11 keys on a computer keyboard. However, the compliance rate for the program since 2022 has averaged 55%, making it hard for the police to assist many of the personnel if they are in danger.

  This project aimed to increase employee compliance for the F9-F11 to ensure a safe environment for everyone. Using the DMAIC approach, we evaluated the root causes of the problem. This senior project team used six-sigma tools during the process, including the use of p-charts to determine whether the process was in control or not.

  As part of the analysis phase, the team used why-because and fishbone diagrams to determine the reasons why the employees weren’t compliant with the program. In addition, the team conducted weekly meetings with Ms. Pamela Cain to discuss project updates and future tasks.

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• Lean Six Sigma Analysis of Patient Discharge Procedures at the San Antonio VA Hospital

  Team: Jorge Abdalah (IE), Juan Carlos Asfura (IE), Ian Freire (IE) and Daniel Matheu Baldor (IE)

  Sponsor: Audie L. Murphy VA Hospital

  The aim of this project was to improve the patient discharge process at Audie L. Murphy VA Hospital of San Antonio by identifying and eliminating inefficiencies in the process. The discharge process, which took approximately 4-6 hours, led to patient dissatisfaction, inefficient resource utilization and increased operational costs. The project was based on the lean six-sigma philosophy; some of the techniques utilized by the senior design team were DMAIC, data collection, fishbone charting, why-because analysis and Monte Carlo simulation on ProModel.

  The project scope encompassed a comprehensive analysis of the current discharge process, data collection on discharge times and resource usage and the application of Lean Six Sigma methodologies using the DMAIC framework in collaboration with the hospital’s lean six-sigma team.

  Key stakeholders included the project team, faculty supervisor, VA hospital supervisors, hospital staff and patients. The project was sponsored by the Veterans Hospital of San Antonio’s Lean Six Sigma Continuous Improvement Team, with oversight provided by the faculty supervisor and hospital supervisors. Project deliverables included process mapping and data analysis, Lean Six Sigma implementation, ProModel simulation, a final report with recommendations and a presentation to VA hospital leadership and faculty.

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• Lean Six Sigma Improvements at the San Antonio Children’s Shelter

  Team: Ariana Aguilar (IE), Salma Alotaibi (IE), Brendan O’Hara (EM), Alexander Small (SE)

  Sponsor: San Antonio Children’s Shelter

  This Business Requirements Document (BRD) was designed to guide the transition of the Children’s Shelter from a paper-based to a digital data management system, with the goal of enhancing operational efficiency and data accuracy. Intended for the San Antonio Children’s Shelter’s management, staff and therapists, the project focused on the shift from manual, error-prone data entry processes to a system where digital forms were integrated with existing databases for operational efficiency processing.

  The scope of the project encompassed system development, staff training and seamless integration with their existing technology and resources, which ensured scalability and incorporation of feedback mechanisms. Key business drivers for the project were improvements in accessibility to data, reduction of time, compliance with HIPAA and ISO standards and the modernization of shelter operations. Our analysis showcased that the manual system was not only deficient but also posed time-consuming measures.

  By transitioning to a digital format, the shelter mitigated these issues, streamlined operations and enhanced therapy services. The requirements included electronic forms, automated data integration, AI, compliance with HIPAA for privacy and bilingual support, ensuring that the new system met the diverse needs of the shelter and its clients.

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• Universal Window A/C Mounting Bracket and Sealing Method

  Team: Elijah Narvaez (ME), Adrian Losoya (ME) and Savannah Youngblood (ME)

  Sponsor: Friedrich Air Conditioning Co.

  This project focuses on the design, construction and testing of a wall-mounted bracket engineered to effectively support a window air conditioner. Window air conditioning units are heavy and require stable support to prevent structural damage to the window frame and ensure safe operation. The objective was to develop a robust bracket that is easy to install, durable and capable of withstanding the forces generated during operation.

  The design process involved analyzing various material options, load-bearing requirements and structural formations to optimize strength while minimizing cost and complexity. Using computer-aided design (CAD) software, several prototypes were modeled and analyzed to predict stress distribution and deformation under load. The selected design utilized high-strength steel components with corrosion-resistant coatings for long-term durability. The bracket was then fabricated and subjected to a series of load tests to validate its performance under simulated operational conditions. Testing confirmed that the bracket could safely support the air conditioner without deformation or instability, ensuring both safety and functionality.

  In addition to enhancing structural stability, the project also focused on improving the sealing method used around the air conditioner to prevent outside air, moisture and other elements from entering the room. A combination of high-density foam insulation and weatherproof sealing strips was integrated into the bracket design to create a tight, energy-efficient seal between the window frame and the unit. This sealing solution not only improves indoor air quality but also enhances the overall efficiency of the air conditioner by preventing cool air from escaping. The final product offers a reliable and user-friendly solution for homeowners seeking to enhance the safety and efficiency of their window-mounted air conditioning units.

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• Low-Cost Dermatoscope with Early Melanoma Detection

  Team: Diego Pensado (ME), Emmanuel Rodriguez (CE) and Brianna Valadez (ES-PreMed)

  Sponsor: Baylor College of Medicine

  Melanoma is one of the most aggressive forms of skin cancer, yet early detection can significantly improve survival rates. Access to diagnostic tools, however, is limited in underserved areas due to cost and availability. To address this issue, this project focuses on developing a low-cost, standalone dermatoscope device capable of capturing high-quality images of moles and integrating machine learning for preliminary diagnostic feedback. The device is designed for universal usability, accommodating diverse skin tones and age groups, while remaining affordable and accessible to healthcare providers globally.

  This senior design project represents an innovative solution to bridge gaps in melanoma detection, leveraging engineering expertise in mechanical design, optics and machine learning. The resulting device will empower users with a preliminary diagnosis and facilitate dermatologist evaluation through secure image transfer.

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• STEM Voyager: Transforming a School Bus into A Mobile STEM Lab to Empower K-8 Students in the SAISD

  Team: Patrick Canez (ME), Fernando Jaime Sepulveda (ES-Env), Jaya McGill (ME), Lexi Nunez (ME), Pedro Reyes Perez (ME) and Gianluca Porzio Cuenca (ME)

  Sponsor: SAISD Foundation

  This project focuses on transforming a school bus into a mobile STEM lab, designed to inspire and educate middle school students while empowering teachers to deliver interactive and engaging lessons. The bus will serve as a traveling educational hub, introducing students to various STEM disciplines in an accessible, hands-on environment. Recognizing the challenges schools face in establishing permanent STEM labs due to cost and space constraints, this project aims to provide a practical and sustainable solution by creating a mobile, adaptable learning platform.

  Key components of the project include designing and implementing technologies that align with educational needs, constructing functional and safe learning spaces within the bus and an interactive environment where students can see how STEM can lead to exciting and fulfilling careers. The bus will be equipped with a robust electrical system to support various technologies, sustainable construction practices and inclusive activities suitable for students of all abilities. By fostering excitement and interest in STEM, the project seeks to encourage students to pursue related careers and strengthen their academic transitions to high school and college.

  Our role emphasizes the design and procurement of materials, while collaborating with sponsors to ensure the bus meets the educational requirements of students and teachers. Additionally, third-party assistance will be enlisted for complex tasks like electrical installations. This mobile STEM lab offers an innovative approach to bridge the gap in STEM education accessibility and creating a lasting impact on the academic journeys of young learners.

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• Speed Measurement on SwRI’s Eco-Marathon Vehicle

  Team: Scott Roelker (CE), Andrew Garza (ME) and Benjamin Openshaw (CE)

  Sponsor: Southwest Research Institute

  Our project focused on replacing the damaged encoder-based speed system on Southwest Research Institute’s (SwRI) Shell Eco-Marathon Vehicle with a more reliable and accurate solution. The original system was damaged during transit and its temporary replacement could not provide reliable speed data above 3 MPH. This limited the state estimation system’s ability to track the vehicle’s speed and direction, especially during autonomous operation.

  To address this, we worked with SwRI to design a new system capable of accurately measuring speeds up to 11.1 m/s (approximately 25 MPH) and transmitting the velocity of the rear wheels and speed of the front wheels to the vehicle’s state estimation system over the CAN Bus. Our approach involved decoding signals from onboard quadrature and single-channel encoders in software using the STM32F401CCU6 microcontroller.

  We built a test bench using an off-the-shelf DC motor and the vehicle’s encoders to validate our decoder’s performance. After successful testing, we finalized the wiring, determined all necessary components and mounted the system within the vehicle. The decoder met all functional requirements in both test bench and in-vehicle testing. As a result, SwRI can now reliably use their vehicle in autonomous competitions and future replacements of the decoder are simplified.

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• Wireless Implementation of the Doppler Pulse Detector

  Team: Ryan Espinosa (EE) and Linda Masabo (EE)

  Sponsor: Baptist Medical Center

  The Doppler pulse detector is an essential medical device used to detect blood flow by transmitting ultrasound waves and analyzing the returning signals. Traditional Doppler pulse detectors consist of a probe and a box housing the speaker. The two parts are connected by a wired link. This design requires both hands of medical professionals and can be cumbersome in emergency scenarios. This project aims to redesign the Doppler pulse detector by transitioning to a wireless or integrated handheld solution that enhances portability without compromising the accuracy or performance.

  To achieve the main objective of this project, two primary solutions were explored: (1) enabling wireless communication between the probe and the control box or (2) developing a singular probe that combines both parts to do the same job effectively. Key design considerations include power management, signal processing and medical safety regulations.

  The system employs two ESP32 microcontrollers, programmed via the Arduino IDE, to wirelessly transmit audio from the Doppler pulse detector. The first ESP32 digitizes the analog signal from the probe, while the second ESP32 receives the digital data, processes it and converts it back to analog for speaker output. Modern tools such as MATLAB for signal analysis, Multisim for circuit simulation and SolidWorks for structural design were utilized in the development process.

  The final prototype aims to improve the ease of use for medical personnel while maintaining the reliability of the Doppler pulse detector. This redesign represents a step toward more advanced, user-friendly Doppler pulse detectors in the medical field.

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• Ultra GPS

  Team: Nnamdi Jesse Omwuzurike (CE) and  Leon Harb (CE)

  Sponsor: Hatchbed LLC

  The objective of this project is to develop an affordable indoor navigation system for autonomous vehicles where GPS is unreliable or unavailable. The system is intended to meet the requirements of educational environments, providing ±5 cm localization precision and update rates of 5 Hz. This project initially explored multiple localization methodologies, including SLAM (Simultaneous Localization and Mapping), Radio frequency-based tracking and ultrasound systems. We ultimately settled with the use of ultrasound, hence the name UltraGPS. The final design integrates cost-effective hardware with real-time data processing, allowing seamless operation both indoors and outdoors. This work aims to create a scalable solution that enhances robotics education by offering practical, hands-on experience with indoor autonomous systems. 

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To view more Engineering Senior Design Projects, check out the Engineering Senior Design Project Archive page.

Become a Sponsor

We would like your input on what types of student projects and partnerships the Engineering Department might support. We create interdisciplinary and cross-functional learning with students, faculty and organizations to provide opportunities for collaboration on real-world projects. Please fill out this form multiple times if you would like to suggest more than one partnership contact.

• Engineering Senior Design Project Sponsorship Form

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