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.

Sponsors

Senior design projects have been sponsored by organizations such as:

  • Audie L. Murphy VA Hospital
  • Baylor College of Medicine
  • Bimbo Bakeries
  • City of San Antonio
  • Cox Manufacturing
  • Direct Source Meats
  • DriverTech
  • Friedrich Air Conditioning Co.
  • Frito-Lay
  • H-E-B
  • Intertek
  • Labatt Food Service
  • Pristech
  • SAISD Foundation
  • San Antonio Airport
  • San Antonio Food Bank
  • San Antonio Lighthouse for the Blind
  • San Antonio River Authority
  • Southwest Research Institute
  • ST Engineering San Antonio Aerospace (SAA)
  • T-Mobile
  • Texas Biomedical Research Institute
  • Zachry Construction
Become a sponsor

Our dream is that every student gets to do deep engineering work by the time they graduate. Because Labatt is an innovator in its field, our partnership with them has been a tremendous résumé-builder for our students.”

Rafael Moras, Ph.D.
Professor of Industrial Engineering

2026 Projects

  • CNF Dead Drop

    Team: Donovan Acosta (SE), Kevin Artola (SE), Ethan Rodriguez (SE) and
    Eric Sifuentes (EE)

    Sponsor: CNF Technologies

    Modern low probability of detection (LPD) activity increasingly rely on digital communication platforms, creating a need for deeper understanding of LPD data transfer techniques. This project presents the design and prototyping of a disguised digital dead drop device capable of short-range peer-to-peer (P2P) communication.

    The system is built around a Raspberry Pi Zero and leverages a WiFi Direct P2P network architecture to establish LPD wireless connections with a companion mobile application. The prototype demonstrates automated data collection and exfiltration mechanisms while maintaining a low physical and electronic profile.

    Externally, the device resembles a benign hobbyist electronics project, while internally it operates as a fully functional transfer node capable of securely storing retrieved data or transmitting it over encrypted radio communication

    View Abstract

  • Autonomous Detection and Tracking of Rising Air For Unmanned Aerial Systems

    Team: Dominic Downing (CE), Andres Faili (CE) and Joshua Riojas (EE)

    Sponsor: American Tenet

    Unmanned Aerial Systems (UAS) can extend flight endurance by exploiting naturally occurring rising air, but autonomously detecting and following these regions remains challenging. This project presents a machine learning based approach for autonomous rising air detection and exploitation. A supervised Machine Learning Model (MLM) classifies the local atmospheric state into three probabilistic categories: inside rising air, at the edge of rising air, or outside rising air, using onboard flight and environmental measurements.

    These probabilistic estimates are provided to a Reinforcement Learning Agent (RLA) that learns a control policy to adjust the drone’s trajectory and remain within regions of rising air while maintaining stable flight. The perception and control components of the MLA algorithm operate in a closed loop, enabling real-time adaptation to changing atmospheric conditions.

    The system is evaluated in a simulated environment with modeled updrafts and sensor noise. Results show that the proposed method enables reliable rising air tracking and relevant air shapes in the real world compared to baseline controllers, demonstrating the effectiveness of combining machine learning perception with reinforcement-learning control for autonomous UAS soaring.

    View Abstract

  • Lean Six Sigma-Based Process Improvement and Software Integration for Operational Efficiency in a Diabetic Care Clinic

    Team: Luz Manchego (IE), Clarissa Nunez (IE) and Joseph Hall (SE)

    Sponsor: Clínicas del Azúcar

    Our team is working to automate and systematically identify inefficiencies at the diabetes clinic Clínicas del Azúcar. Through data analysis, lean methodologies and software-based models. We aim to improve patient flow efficiency while reducing the risk of human error.

    View Abstract

  • Food Bank Warehouse Efficiency and Process Improvement

    Team: Maria Fernanda Galdamez (IE) and Javier Velez Carmona (EM)

    Sponsor: San Antonio Food Bank

    Nonprofit food banks operate within constrained environments characterized by limited financial resources, variable demand and reliance on volunteer labor, making operational efficiency critical to service delivery. The San Antonio Food Bank warehouse experienced inefficiencies in receiving, storage and order prioritization processes, resulting in congestion, extended processing times and inconsistent inventory organization.

    This senior design project applied Industrial Engineering and Engineering Management methodologies to analyze and improve warehouse operations using the Lean Six Sigma DMAIC framework. Quantitative and qualitative data were collected through time studies, direct observation, analysis of historical receiving and order data and interviews with warehouse personnel.

    Baseline performance metrics were established to evaluate current-state operations. Analysis identified key contributors to inefficiency, including suboptimal warehouse layout, inadequate inventory zoning, excessive material handling and lack of standardized order prioritization. Industrial engineering tools such as value stream mapping, ABC classification, FIFO inventory management and slotting optimization were employed to assess process performance and identify improvement opportunities.

    The proposed improvements emphasize cost-effective and feasible solutions suitable for a nonprofit context, including demand-based inventory zoning, standardized prioritization criteria, redesigned receiving-to-storage workflows and enhanced visual management. Simulation modeling was used to evaluate alternative layout configurations and estimate performance impacts.

    The proposed solutions are expected to reduce internal travel distances by approximately 15–30%, decrease congestion in high-traffic areas and improve consistency in order fulfillment. This project demonstrates the applicability of data-driven process improvement and Lean Six Sigma methodologies in nonprofit food distribution environments, highlighting their potential to enhance operational efficiency, sustainability and service effectiveness without significant capital investment.

    View Abstract

  • Six Sigma Based Productivity Improvement at the San Antonio Food Bank

    Team: Paloma Soforo Grelier (ES) and Alex Trevino (CE)

    Sponsor: San Antonio Food Bank

    This internship-based project was conducted at the San Antonio Food Bank to support the design of a systematic process for managing daily donation deliveries from major donors, including H-E-B. Unlike other donors, H-E-B requires that its donated goods not accumulate in inventory, creating a unique operational challenge for warehouse staff.

    Prior to this project, donated pallets were frequently placed in ad hoc locations throughout the warehouse, leading to congestion, inefficient retrieval and inconsistent processing times. Using the DMAIC methodology, the project team analyzed current donation handling practices, identified sources of delay and variability and developed a structured system for the daily intake, staging and routing of donated goods.

    In parallel, software engineering tools were applied to design a digital solution that supports real-time tracking of incoming deliveries, standardized placement rules and improved visibility for warehouse personnel. The resulting system reduces randomness in pallet placement, increases process consistency, and enhances the Food Bank’s ability to efficiently manage high-volume daily donations while meeting donor-specific requirements.

    This framework provides a scalable approach to warehouse flow optimization for future operational improvements.

    View Abstract

  • Simulation and Ergonomic Analysis of a Redesign Fast-Food Kitchen Layout

    Team: Gabriel Tello (IE) and Samuel Orozco Salazar (IE)

    Sponsor: Whataburger

    This senior design project evaluated Whataburger’s Enhanced Throughput Kitchen (ETK), an innovative kitchen layout developed to improve operational efficiency, throughput and employee ergonomics while maintaining made-to-order food quality. Sponsored by Whataburger and conducted in collaboration with the Innovation Team, the study compared the ETK prototype against the existing kitchen layout using industrial engineering methodologies grounded in Lean Six Sigma principles.

    The project applied a structured DMAIC framework to guide analysis and improvement efforts. Time and motion studies were conducted to quantify cycle times, task sequences and employee movement across key workstations. Queuing and workflow analyses were used to identify bottlenecks and capacity imbalances during peak demand periods.

    Ergonomic risks were evaluated using OSHA- and NIOSH-aligned tools, including RULA and REBA, to assess workstation design and employee posture. Process mapping techniques such as Value Stream Mapping and 5S were employed to identify non-value-added activities and opportunities for workflow simplification. Simulation modeling and statistical distribution fitting were used to represent workstation processing times and validate system behavior under different operating conditions.

    The analysis focused on measuring efficiency improvements, reducing operational bottlenecks, minimizing waste and validating ergonomic enhancements within the spatial and operational constraints of the pilot restaurant. The findings of this project provide data-driven insights and recommendations to support Whataburger’s decision-making prior to full-scale ETK implementation.

    Overall, the study demonstrates how simulation, Lean methodologies and ergonomic analysis can be integrated to enhance performance and sustainability in fast-food operations.

    View Abstract

  • Reusable Glycol Testing System for FBD Machines

    Team: Valerie Hover (ME), Jacob King (ME) and Daniel Vogt (ME)

    Sponsor: Frozen Beverages Dispensers

    This project aims to develop a reusable testing system for Frozen Beverage Dispensers (FBD) Frozen Carbonated Beverage (FCB) machines. Current test control protocols rely on single-use syrup, costing the company approximately $70,000 annually.

    The proposed solution involves designing and implementing a closed-loop system with a supplemental reservoir that circulates propylene glycol- a low-toxicity, effective heat-transfer fluid-through the FCB machine’s barrel. This system will apply a consistent thermal load to the refrigeration unit during testing. Key design parameters include maintaining the glycol exit temperature at a constant 26 degrees Ferenheight and ensuring system safety and compatibility with existing manufacturing facilities.

    The final deliverables will include the functional hardware system, detailed engineering documentation, operating instructions and proof-of-concept testing data, enabling FBD to integrate the cost-saving, efficient and repeatable testing methodology into its standard production assessments.

    View Abstract

  • SwRI Mechanical Ground Support Equipment Eco-Marathon Vehicle

    Team: Aiden Garcia (ME), Carlos Gauna (ME) and Jose Perez (ME)

    Sponsor: Southwest Research Institute

    This project focuses on developing a complete design for mechanical ground support equipment capable of lifting and positioning space hardware inside a new thermal vacuum chamber at Southwest Research Institute.

    The chamber uses an internal I-beam to suspend the unit under test, which requires a handling system that can safely guide the hardware into place while accommodating the tight space around the chamber opening. Our team created a modular concept using SolidWorks models, structural simulations and feedback from SWRI engineers to shape a design that fits the facility and meets the required safety expectations.

    The final result is a detailed set of drawings for a system that can adjust to different future test articles. Further analysis and refinement will continue in the next phase of the project as the design moves toward a fully validated solution.

    View Abstract

  • Test Rig Design for D2809 Standard

    Team: Efren Paita (ME) and Yareli Zelaya (ME)

    Sponsor: Intertek San Antonio Automotive Research

    This project focuses on the design, construction and evaluation of a test method to assess cavitation corrosion and erosion-corrosion behavior in aluminum automotive water pumps exposed to engine coolants. Using the ASTM D2809-21 standard as the testing framework, the team develops a controlled pressurized loop capable of replicating operating conditions found in vehicle cooling systems.

    Cavitation occurs when vapor bubbles collapse against the pump surface, causing pitting and material loss, while coolant chemistry can accelerate corrosion; together, these mechanisms significantly reduce pump durability and efficiency. The test rig will allow systematic comparison of multiple coolant formulations by quantifying pump impeller degradation through standardized rating criteria.

    The system will be designed for safety, mechanical stability, mobility within laboratory constraints and straightforward use by technicians. This work will provide an industry-relevant tool for identifying coolant performance, improving pump reliability and supporting research on cavitation–corrosion interactions in modern automotive components.

    View Abstract

  • Condensate Transfer System

    Team: Manuel Palma (ME) and Manuel Urbina (ME)

    Sponsor: Friedrich Air Conditioning Co.

    This project explores three design concepts intended to improve condensate management within a residential HVAC air-handling unit: a mist system, a pump-and-reservoir system and a custom drip-pan extension.

    Each design aims to control or redirect condensate more efficiently than the existing factory configuration. Psychrometric calculations were completed under four environmental conditions to estimate real-world condensate generation, producing a range from approximately 0.02 to 2.77 liters per hour. Heat-transfer calculations were also performed to evaluate how the presence of standing water beneath the evaporator coil affects cooling performance and how the new drip-pan extension influences thermal resistance when installed between the coil and the original drip pan.

    Although the PETG material adds insulation at the point of contact, the elimination of standing water reduces re-evaporation losses and improves latent cooling, resulting in a net coil efficiency gain of approximately 4-5%. Each of the three prototype designs was evaluated for manufacturability, cost, functionality and long-term performance. The report summarizes the engineering analysis, testing and final justification for the selected solution.

    View Abstract

More Engineering Senior Design Projects

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

View Project Archive

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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