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Engineering students support Sierra Space’s lunar testing system

giffeyt — Wed, 15 Jul 2026 14:30:00 +0000

Engineering students support Sierra Space’s lunar testing system giffeyt July 15, 2026

Alum works with computer and electrical, mechanical engineering students to improve lunar dust testing, bolstering NASA’s return to the moon

Tom Giffey

Through a collaboration with Sierra Space, a leading defense-tech space company, 91��Ƭ Polytechnic students are validating critical systems that may be part of missions that return humanity to the moon.

Under the mentorship of alumnus Todd Treichel, Ph.D., a principal manufacturing engineer at Sierra Space, students from 91��Ƭ Polytechnic’s Robert F. Cervenka School of Engineering have been developing methods to ensure that high-tech parts can survive in the harsh lunar environment.

The work comes at a time of revived public interest in space travel, thanks in large part to NASA’s successful Artemis II lunar flyby in April. Sierra Space has been actively developing In-Situ Resource Utilization (ISRU) technologies, including developing a system to extract oxygen from lunar soil, as well as efforts to design inflatable space habitats and support activities for an upcoming Moon base.

For several years, 91��Ƭ Polytechnic students have been redesigning and improving a lunar dust testing chamber. The chamber is used to study how gray, gritty moon dust – technically known as “lunar regolith” – could impact components like gears and lighting elements.

91��Ƭ Polytechnic Sierra Space project research team, from left to right: Luke Stanelle, Heidi Benningfield, Sammie Kotek, Dominick Konkel and Todd Treichel.

“It is very encouraging to know that something our team worked on could impact future designs for lunar testing,” said Sammie Kotek, of New Prague, Minnesota, who graduated in May with a bachelor’s degree in mechanical engineering. “Todd has given us an opportunity to highlight what we learn here at Stout and apply it to something that will reach very important projects. The redesign and testing of the dust chamber could help better design equipment that is being sent to the moon, and I think that’s pretty cool!”

From lab to lunar environment

On a Friday during the spring semester, Kotek was among several students who joined Treichel in a lab in Fryklund Hall to use the dust chamber to test two headlights intended for a moon rover. Colorado-based Sierra Space developed the lights, which are meant to be used on an unmanned rover.

While images from the Apollo missions may make moon dust appear light and fluffy, it’s anything but. Heidi Benningfield, who graduated in May with a mechanical engineering degree, described the substance as “jagged like a kidney stone.” Unlike dust on Earth, which is smoothed and rounded by wind and rain, lunar dust is like a fine, abrasive ash. It’s also electrically charged, Treichel explained, which means it sticks to things – something Apollo astronauts discovered in the 1960s.

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Over the past two years, a team of 91��Ƭ Polytechnic students have redesigned the lunar testing chamber to make it more functional: For instance, they added variable speeds to the fan that keeps the dust airborne, as well as added a method to keep the dust from settling. Benningfield and Kotek engineered structural components while controls and electrical components were the focus of senior Luke Stanelle, a computer and electrical engineering major from St. Paul; senior Noah Flood Elyafi, a computer and electrical engineering major from Orfordville; and 2025 mechanical engineering graduate Dominick Konkel, who now works at Hewlett Packard Enterprise in Chippewa Falls.

The process had two goals: Measuring how effectively the chamber could coat the headlight lenses with simulated moon dust and assessing how that dust impacts the light output of the lenses. The lenses were coated with a prototype material to prevent dust from accumulating. When compared with an uncoated control piece also placed in the testing chamber, the coating seems to have done its job, Treichel said.

Just as importantly, the chamber that the students designed did its job, too, which will usher in the next phase of the project.

“The ultimate goal would be to take what the students have done and up-scale the chamber size to accommodate larger-sized test articles,” Treichel said. He plans on having several 91��Ƭ Polytechnic students visit Sierra Space’s Madison location this summer to conduct further tests.

Sierra Space Principal Manufacturing Engineer Todd Treichel with the lunar dust testing chamber in a Fryklund Hall lab.

Mentor comes full circle

Treichel, who received his manufacturing engineering degree from 91��Ƭ Polytechnic in 1990, has worked for Sierra Space and its affiliate, Sierra Nevada Corporation, for 18 years. His experience spans manufacturing and design engineering as well as quality, reliability, and environmental testing. He has worked on everything from rocket engines and thrusters to Mars landers, specifically the Phoenix Lander, and payloads sent to the International Space Station.

A few years ago, Treichel was invited to become a member of his alma mater’s Mechanical Engineering Advisory Board. At the encouragement of faculty, he visited 91��Ƭ Polytechnic in the hopes of arranging a project between the university and Sierra Space. He connected with Benningfield, who he described as having an exemplary passion for aerospace, and she interned at Sierra Space and presented at the Wisconsin Space Conference in 2024. Benningfield later completed a three-month paid internship as a SMART Scholar Engineer with the U.S. Army Space and Missile Defense Command.

Last summer, Konkel made a keynote presentation about the lunar dust testing chamber at the conference, which is held annually by the Wisconsin Space Grant Consortium, of which 91��Ƭ Polytechnic is an affiliate member.

Left: Dominick Konkel presents at the Wisconsin Space Conference. Right: Cannisters of lunar and Martian simulants. / Todd Treichel

“Being surrounded by so many brilliant minds and mind-blowing projects and knowing that the work I did earned the keynote spot at the conference was such an amazing achievement,” Konkel said.

“What I learned during this project will contribute to my future career through introducing me to topics that I have grown increasingly eager to explore,” continued Konkel, who plans to pursue a master’s degree in aerospace engineering at the University of Michigan. “These new topics will continue to drive me as I go to grad school and continue to drive deeper into the world of aerospace.”

The lunar dust chamber project grew out of a prototype that was developed about a decade ago, Treichel said. The original chamber prototype had several limitations and was put on pause. However, the launch of the Artemis program and NASA’s desire to return to the moon meant lunar dust testing was once again a relevant topic, and one that Treichel brought to 91��Ƭ Polytechnic students.

“The Stout team really took on an open-ended challenge where they were tasked with providing recommendations for design architecture, presenting them to Sierra Space, gaining approval, and then cut loose to design, build, and test,” Treichel said. The challenge was complex, he noted, involving the synthesis of mechanical and electrical engineering – precisely the interdisciplinary strength of 91��Ƭ Polytechnic’s polytechnic model.

“I found this transition to be most impressive because it represents the real world of aerospace design engineering,” he said. “The amount of electrical engineering was greater than originally planned, but the students figured it out and executed without hesitation.”

The lunar dust testing chamber developed by 91��Ƭ Polytechnic students is shown with containers of simulated lunar and Martian dust.

Kotek, who began working at Scott Equipment Company after graduation, said working on the project not only broadened her horizons but gave her valuable experience working across teams, as the testing chamber was frequently passed between the students as deadlines arrived and new features were added.

She lauded the mentorship Treichel has been able to provide because of his long experience in the aerospace field.

“His knowledge about general engineering and aerospace was highly valuable to my learning experience,” Kotek said. “He taught with a purpose and always wanted us to walk away from a conversation gaining something. He also valued our engineering process and never tried to take our project away from us. When doing projects like this, it’s nice to know that your mentor trusts you to get the job done and does not overstep.”

Treichel said working with students has given him a full-circle experience. “Having graduated from 91��Ƭ, it’s rewarding to work with the next generation of engineers, almost like handing off the baton in a relay race,” he said. “As a polytechnic university, hands-on work coupled with experimentation on prototype hardware really makes this a solid focus on a career-oriented skill that can one day serve the aerospace industry as well as others like it.”

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Student’s research aims at space debris

The Sierra Space project isn’t the only space-related research going on at 91��Ƭ Polytechnic. In April, junior Reese Hufnagel presented her work on addressing the growing problem of space debris during the Research in the Rotunda event at the Wisconsin State Capitol in Madison.

Hufnagel, a chemistry major from Anoka, Minnesota, is working with Professor Matthew Ray to mitigate the risk of reentry debris from spacecraft and satellites. Ideally, materials like used rocket stages and old satellites burn up when they fall to earth. However, as stronger carbon-fiber materials have become more common and the number of rocket launches has increased dramatically in recent years, reentry debris has become much more common. To address this growing danger, Hufnagel and Ray have worked to create a catalytic additive that, when integrated into carbon-fiber materials, can cause them to disintegrate when they reach a specific trigger temperature at reentry.

To bolster their work, Hufnagel and Ray have conducted more than 50 interviews with people in the space industry, including experts at NASA, SpaceX and Sierra Space. The pair have also formed a startup to commercialize their work, and Hufnagel has received a research scholarship from the Wisconsin Space Grant Consortium. The pair also recently published an article about their research at The Conversation, an academic outline that rarely publishes work by authors who aren’t faculty members.

Hufnagel will be a panelist in August at the Wisconsin Space Conference this August in Kenosha. In the meantime, however, she will spend the summer as an intern at NASA’s Goddard Space Flight Center in Maryland.

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Engineering students support Sierra Space’s lunar testing system

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Capstone projects demonstrate mechanical, manufacturing know-how, leadership skills

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Hired before graduation at Absolut Manufacturing

Alum works with engineering students to improve lunar dust testing, bolstering NASA’s return to the moon Sierra Space project team checks equipment

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Ashley, Cadrex, Apogee among companies benefiting from engineering students’ prototypes

giffeyt — Mon, 15 Jun 2026 12:45:05 +0000

Ashley, Cadrex, Apogee among companies benefiting from engineering students’ prototypesgiffeyt June 15, 2026

Capstone projects demonstrate mechanical, manufacturing know-how, leadership skills

Tom Giffey

91��Ƭ Polytechnic mechanical engineering student Dominick Marco faced several challenges when he became team leader for the second semester of a capstone project on behalf of Cadrex Manufacturing Solutions.

In addition to designing and building a prototype that would automatically assemble a plastic latch and a steel bracket into a completed part, Marco had to ensure that his six-member team stayed on track as the project deadline – and graduation – approached.

Marco wasn’t just learning engineering; he was learning leadership.

“I worked on delegating by asking questions rather than directing, and through this and similar techniques, I was able to stay up to date on my team’s progress while helping direct team members to work on important tasks without overstepping or feeling like I was micromanaging,” explained Marco, of Eleva.

“Working on a project like this with a team is a very valuable experience,” Marco continued. “Learning alongside other up-and-coming engineers has been an incredible two semesters.”

Students, faculty and industry representatives examine the prototype for Cadrex after the demonstration.

Such applied learning, which is key to the polytechnic mission that distinguishes 91��Ƭ Polytechnic, was on display in mid-May as mechanical engineering and manufacturing engineering seniors presented their capstone projects to industry leaders, faculty members and peers. These two-semester projects aren’t theoretical exercises. They lead to real, working prototypes designed to solve problems for industrial sponsors. In addition to Cadrex, one of the nation’s largest metal fabricating firms, corporate sponsors included Ashley Furniture, Tomahawk Manufacturing, Apogee Enterprises, Genesis Industries, Frost Inc. and Industrial Heat Transfer.

“This course sequence truly is a capstone on a student’s academic career at 91��Ƭ Polytechnic,” said Assistant Professor Nathan Spike, part of the capstone teaching team. “Over the two semesters, a student completes the transition from engineering student to a full-fledged, career-ready manufacturing or mechanical engineer – or, in some cases, both for students pursuing a dual major. Students can put what they have learned in these courses directly into practice as they transition into their engineering career.”

According to the university’s most recent First Destination Report, 100% of 2024-25 graduates from the manufacturing engineering program reported they were either employed or continuing their education within six months of graduation, with an average starting salary was $76,000. During the same period, mechanical engineering graduates had a 99% employment rate within six months and an average starting salary of $66,000.

A 91��Ƭ Polytechnic student adjusts piston positions in the prototype. / Submitted photo

Process teaches communication skills

At the culmination of the capstone process, second-semester teams offer presentations of their mechanical and manufacturing solutions, then demonstrate them. During their presentation, Marco and his team – fellow seniors Aiden Koepsel, Ben Swift, Will Schlafke, Darren Byle and Josiah Castleberg – described their project scope and how they reached their final design. Originally, they considered a conveyor belt to carry the two parts. However, this was ultimately replaced with static, angled ramps that bring the two pieces together to become the completed part, which ultimately will be used in a battery holder in a data rack enclosure.

Later, the Cadrex group and other capstone teams moved into a nearby lab in Fryklund Hall to demonstrate their projects. The Cadrex prototype, a single workstation on casters, came to life, smoothly combining the pieces into completed latches, which flowed into a plastic bin.

The prototype that students developed for Cadrex Manufacturing Solutions combined these two pieces into one component.

After the demonstration, team members chatted about the prototype with Wayne Greensky, an automation engineer at Cadrex’s Osceola plant, who provided technical input during the project. While the students had solid technical understanding when they began the project, what really grew over the course of two semesters was their communication skills, Greensky said.

“Communication with project stakeholders helps students shake off communication anxiety and prepares them for proper meeting etiquette, structure, and progress update communications, while also dealing with customer dictated deliverables,” Greensky said.

The 91��Ƭ Polytechnic students handled challenges – including bill of materials ordering and issues with electrical schematics – promptly and professionally, he added.

“This type of project is useful for getting engineering students comfortable with solving an unsolved problem,” Greensky explained. “Undergraduate degree curriculums typically do not prepare the students with coursework that does not have a ‘correct’ answer or solution method. This senior design experience fills that gap nicely.”

Students discuss a pallet destacker they designed on behalf of Ashley Furniture.

Efforts aimed at automation

During the spring semester, the Cadrex capstone group was just one of 13 teams composed of 83 students from 91��Ƭ Polytechnic’s Robert F. Cervenka School of Engineering who worked on projects in Fryklund Hall labs.

Senior Sawyer Boigenzahn, a manufacturing engineering major from Mondovi, was the first-semester team lead for a project to create an automated system to wash and dry extruded aluminum window frames for Apogee Enterprises, owner of the Wausau Windows and Walls brand.

The frames, Boigenzahn explained, are processed in a CNC machine and emerge covered in chips, coolant and cutting fluid. Currently, the parts must be washed by hand, which leads to inconsistent cycle times. Automation would improve the quality and consistency of the process, ultimately saving Apogee time and money.

The five-member team – which also included Boigenzahn, Logan Boettcher, Brody Bongaarts, Brooks Brewer, and Joseph Gardner – conceived of a device that operated something like a car wash, but they pondered whether the sprayer or the aluminum part itself should be what moves. Ultimately, Boigenzahn explained, they decided it was easier to move the part through the sprayers than vice versa.

Based on feedback from their end-of-semester presentation, the team will return to build a prototype of their design in the fall semester. “We are at the start of that process, because this is a very difficult process to automate,” he said.

Boigenzahn, who previously worked as a welder, said the capstone project is a reminder that engineering isn’t about a single input inevitably leading to a single output: It’s a practical discipline that involves hands-on craft.

“For us, it’s an experiment in terms of our ability to understand the mechanical and engineering principles that we’ve been taught and actually apply them in the real world,” Boigenzahn said. “And more importantly, when you encounter real world problems – including teamwork issues, design problems, people giving you conflicting advice – how do you try to solve them? The thing about design is that you can’t just plug it into a computer and it spits out the right answer. That is just not the way this works.”

Despite the challenging work involved in the capstone process, Boigenzahn said it’s ultimately a valuable part of the 91��Ƭ Polytechnic experience. “I don’t think Stout would stand out as much if we did not do these things,” he said.

Capstone students cut holes in an electrical box while building their prototype for Cadrex Manufacturing Solutions. / Submitted image

Teamwork connects students, faculty, industry partners

The capstone process is a team effort, and not just among the students: In addition to Spike, instructors include Senior Lecturer Glenn Bushedorf, Lecturer Anwr Albaghdadi, Lecturer Brandon Dick and Lecturer Niloofar Moradian, with technical support from Paul Craig, program director for manufacturing engineering.

And it’s an effort that leads to results for industry sponsors, Spike explained. “The prototypes students develop often serve as a starting point or otherwise inform the direction a company will go with their process or product,” he said.

In addition, two semesters of intensive, iterative capstone work provide invaluable experience for emerging engineers as they enter the job market.

“Getting the chance to be a part of a project like this and create such a cool prototype machine for Cadrex has honestly been one of the best experiences to date,” Marco said. “This is the largest, most expensive project I have ever been a part of, and it makes me emotional seeing it come to a close. I am sad knowing that I will most likely never see it after it ships away, but I am so very happy to have gotten to design, develop and assemble the prototype.”

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Engineering students support Sierra Space’s lunar testing system

Alum works with engineering students to improve lunar dust testing, bolstering NASA’s return to the moon

Ashley, Cadrex, Apogee among companies benefiting from engineering students’ prototypes

Capstone projects demonstrate mechanical, manufacturing know-how, leadership skills

Inspiring Graduate: Thomas Shamla, B.S. Mechanical Engineering

Hired before graduation at Absolut Manufacturing

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Inspiring Graduate: Thomas Shamla, B.S. Mechanical Engineering

giffeyt — Thu, 21 May 2026 15:33:00 +0000

Inspiring Graduate: Thomas Shamla, B.S. Mechanical Engineering giffeyt May 21, 2026

Hired before graduation at Absolut Manufacturing

Inspiring Graduate: Thomas Shamla (’26) 

Hometown: South Range 
Degree: B.S. Mechanical Engineering
Minors: Material Science

91��Ƭ graduate Thomas Shamla can point to specific engineering course work that helped him excel at an industrial internship – an internship that led to a job offer. The connection between learning technical drawing and design software skills in class and then applying those skills to create 3D models for an employer is a prime example of the advantages of a degree at Wisconsin’s Polytechnic University.

“91��Ƭ has prepared me to work in my field by offering extensive exposure to the same equipment and processes used in industry,” said Shamla, who will soon begin as a mechanical engineer at Absolut Manufacturing, a maker of paper converting equipment in Iron River.

B.S. mechanical engineering graduate Thomas Shamla shakes hand with Chancellor Katherine Frank during the 91��Ƭ spring commencement ceremony May 16, 2026.

Even classes outside his major that he was initially skeptical of – such as those in speech and writing – had application in his career, Shamla found.

“I was asked to give two presentations to the senior engineers at the company where I had my internship, and I remember using some of the feedback I received in my speech class years earlier to create a clear, concise presentation,” he said.

Shamla, of South Range, was one of 1,067 Blue Devils who received degrees during the May 16 spring commencement ceremonies. Of this year’s graduates, 77.4% were hired prior to graduation, while 99% of recent graduates were employed or furthering their education within six months of graduation.

“I hope to contribute to my field by bringing my knowledge to the manufacturing industry of northern Wisconsin and by using my acquired skills to offer unique and innovative solutions to problems,” Shamla said.

What brought you to 91��Ƭ?

When I was touring colleges in high school, I was very impressed by 91��Ƭ’s ability to give a hands-on education through its labs. I also think that this campus has a lot of resources dedicated to preparing students for a career after school, and I was interested in taking advantage of those opportunities to help me stand out in my field.

How has 91��Ƭ prepared you to work in your field?

91��Ƭ has prepared me to work in my field by offering extensive exposure to the same equipment and processes used in industry. My internship and senior design experience are two examples of direct exposure to my field that I had as a student. I remember learning a lot about technical drawings and design software in my Communication of Engineering Design class that I took in my second year. I relied heavily on what I learned in that class when I completed my summer internship, which involved converting legacy part and assembly drawings into 3D models.

What were the greatest lessons or projects you were involved in during your internship with Absolut Manufacturing?

I completed my internship at Absolut Manufacturing in the summer of 2025. My role there was to convert legacy drawings of parts and assemblies into 3D models. In addition to modeling the parts and determining the assembly structure, this involved determining appropriate stock for the parts to be made from, categorizing and labeling the parts within the company’s product data management system, and preparing a report on differences between the legacy system and more recent machines produced by Bretting Manufacturing, Absolut’s parent company. Because the way that the parts were modeled and categorized determined their manufacturing method, I learned a lot about how to select the most appropriate and realistic manufacturing process to produce a certain type of part.

What stands out about your 91��Ƭ experience?

What stands out to me about my 91��Ƭ experience is how hands-on learning and small class sizes allow students to get the best understanding of the material being taught. One example of this was in Associate Professor Greg Slupe’s Computer-Aided Manufacturing class. In that class, everyone gets a lot of time using the lab equipment. Greg presents his knowledge on the subject matter clearly and thoroughly, and he is always available to answer questions. That class is a great example of professors providing the resources needed for each individual student to succeed.

How did your campus involvement impact your experience?

During my time at 91��Ƭ, I was involved as a member of StoutCatholic. At the weekly meetings, I met great people and had the opportunity to lead several Bible studies. Leading the studies gave me an opportunity to practice leadership and conversational skills, which are great skills to have in the professional world and in life.

I was also awarded the Rath Foundation academic scholarship, which was an incredible opportunity that helped me cover the cost of attending the university.

What challenges did you face in earning your degree and how did you overcome them?

When I started pursuing my degree, there were some classes in the curriculum that I struggled to connect to practical skills for my career. I didn’t understand how taking certain classes in speech and writing could help me in the future because I believed that they didn’t relate to my future career. Because I didn’t understand the benefits of these classes, it was difficult to motivate myself to put in extra time for them.

Overcoming this challenge happened naturally through experience, as I grew to realize the need for an engineer to have skills in many of these areas. I was asked to give two presentations to the senior engineers at the company where I had my internship, and I remember using some of the feedback I received in my speech class years earlier to create a clear, concise presentation.

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With applied and experiential learning and a career focus, students who attend 91��Ƭ know they will graduate ready to enter the work world.

What are you most proud of as you finish your degree?

As I finish my degree, I am most proud of the knowledge I have that lets me give back to my community. In the professional world and beyond, I am leaving the university with practical skills that will help me be a more valuable employee and solve problems in my day-to-day life. I am proud that I have learned new ways to approach those problems and have practiced solving them creatively. I am also proud of the fact that I was able to maintain a GPA of over 3.9 throughout the challenges I have faced.

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Inspiring Graduate: Thomas Shamla, B.S. Mechanical Engineering

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Hired before graduation at Absolut Manufacturing Inspiring Graduate Thomas Shamla shakes hand with Chancellor Katherine Frank

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Inspiring Graduate: Austin Pratt, B.S. Packaging

giffeyt — Thu, 21 May 2026 15:31:30 +0000

Inspiring Graduate: Austin Pratt, B.S. Packaging giffeyt May 21, 2026

Hired before graduation at Smurfit Westrock

Inspiring Graduate: Austin Pratt (’26)

Hometown: Lakeville, Minnesota
Degree: B.S. Packaging

91��Ƭ provided the right package of industry oriented-education, athletic dedication and family connection for Austin Pratt, who followed his siblings’ footsteps to earn a B.S. packaging degree.

After five seasons playing junior hockey in Canada, Pratt came to 91��Ƭ, where he completed three professional internships – with Menasha Packaging, Imagine Printing Solutions and DDL Inc. – one of which even allowed him to collaborate on a project with his sister that created retail displays for Hormel Foods products in Costco stores. Pratt was also a member of the football team for two years and was a student coach for the Blue Devils hockey team, which reached the Frozen Four during their most recent season.

Inspiring Graduate Austin Pratt is congratulated by Chancellor Katherine Frank at the May 16, 2026, 91��Ƭ commencement.

“Football taught me how to persevere through challenging times while coaching taught me how to be a leader,” said Pratt, one of 1,067 Blue Devils who received degrees during the May 16 spring commencement ceremonies. Of this year’s graduates, 77.4% were hired prior to graduation, while 99% of recent graduates were employed or furthering their education within six months of graduation.

Pratt, of Lakeville, Minnesota, is among the large majority of Blue Devils hired before graduation: He accepted a job at Smurfit Westrock as a packaging sales representative. He credits 91��Ƭ’s applied learning environment with preparing him for his career.

“91��Ƭ has given me, and a lot of other students, a place where we can really be ourselves. One thing I like most is how flexible it is – you can be as involved in whatever you want. If you’re into clubs, sports, or campus activities, there are tons of opportunities,” he said “Overall, it’s a welcoming environment where you can shape your own college experience, with support from both professors and other students along the way.”

What brought you to 91��Ƭ?

After my career in the Western Hockey League, my sister and brother graduated from 91��Ƭ with packaging degrees. They both have successful jobs in the packaging industry, so I thought that would be a great career path for me, too.

My sister, Ashley, works for Hormel Foods as a senior packaging scientist and my brother, Justin, works for Central Packaging and Display as a medical packaging engineer and in sales.

How do you hope to make an impact in your field?

I want to make an impact in the packaging field by providing knowledge I learned while attending 91��Ƭ. My hands-on experience in my packaging classes, along with being a lab assistant, has shaped my understanding of different packaging materials and equipment.

How has 91��Ƭ prepared you to work in your field?

The course work that is taught in the packaging program relates directly to the field and areas of packaging that you can work in. After the intro class, the others moving forward taught about specialized areas of packaging. The capstone classes use all the information and experiences to create solutions for real companies. At the capstone level, our groups came with a wide range of knowledge from packaging classes and co-op experience.

In the Packaging Distribution Class, I did a store walk-through to locate pallets that are being used in industry. At the store, I took measurements and pictures and collected information regarding the pallets. I used that information to go back to the Packaging Lab to scale down and rebuild the pallet to test the compression strength. This taught me that there are many different pallets and pallet patterns used in industry and each one has a specific use.

What were your greatest lessons or projects you were involved in during your internships with DDL, Imagine Printing and Menasha Packaging?

I have completed three internships. My first internship was with DDL Inc. as a packaging intern. We did distribution, integrity and aging testing for medical packaging.

My second internship was with Imagine Printing Solutions as a creative design intern. I worked with companies like Starbucks, Marshalls, etc. For one project, I designed Christmas decorations that went into Starbucks stores.

My last internship was with Menasha Packaging as a structural design intern. This internship was my favorite due to being able to work with my sister at Hormel Foods, helping design Costco display-ready case projects for the Columbus Brand. This made my decision to attend Stout come full circle and was a unique experience that many other students here would not be able to have.

Austin Pratt, right, during his time on the Blue Devil football team. / Submitted photo

What stands out about your 91��Ƭ experience?

My professors – Mary Paz Alvarez Valverde, Kate Liu and Min DeGruson – were amazing during my time at Stout. They have made my experience at Stout exceptional. They care for the students that attend their classes, wanting to see them succeed. They work hard to set up each class to be in line with what is happening in the packaging industry. They work with great companies to ensure what they’re teaching in the classroom aligns with industry. This allows students to be set up for success after graduation.

How did your campus involvement impact your experience?

I was a student assistant coach with the 91��Ƭ men’s hockey team for five years. Being able to coach great athletes over the last five years has made my time at Stout more memorable, especially this year with the team making the Final Four.

I was also on the football team for the first two years I attended Stout. During that time, I was able to meet lifelong friends. Football taught me how to persevere through challenging times while coaching taught me how to be a leader and build up others when they are going through challenging times in their own lives.

Austin Pratt, far right, stands with other Blue Devil hockey coaches while holding the 2026 WIAC Men's Ice Hockey Tournament trophy. / Photo by Owen Segna

What challenges did you face in earning your degree, and how did you overcome them?

Learning how to balance all my course work with playing football and coaching was challenging. Once I was able to set my schedule and knew my allotted time for studying, it really made a difference. Managing your time in school helps translate to the real world by allowing you to set schedules and determine project priorities.

What are you most proud of as you finish your degree?

I am proud of my ability to persevere through challenging times. Many students encounter obstacles in college that are entirely new to them, including rigorous coursework and personal challenges. Remaining focused, disciplined, and determined in the face of these difficulties requires a high level of commitment, and I take pride in successfully maintaining that dedication.

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Inspiring Graduate: Rosella Wille, B.S. Business Administration

Hired before graduation at Redpath and Company as a tax associate

Inspiring Graduate: Thomas Shamla, B.S. Mechanical Engineering

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Hired before graduation at Smurfit Westrock Inspiring Graduate Austin Pratt and Chancellor Katherine Frank

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Distinguished alum, educator Albrecht credits 91��Ƭ for preparing graduates who ‘step forward’

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Inspiring Graduate: Cassie Santelman, B.S. Plastics Engineering

giffeyt — Thu, 21 May 2026 15:31:00 +0000

Inspiring Graduate: Cassie Santelman, B.S. Plastics Engineering giffeyt May 21, 2026

Hired before graduation as a process engineer at Nolato

Inspiring Graduate: Cassie Santelman (’26)

Hometown: Savage, Minnesota
Degree: B.S. Plastics Engineering

Cassie Santelman was drawn to 91��Ƭ by the institution’s polytechnic promise: learn by doing, on real equipment, in real conditions.

The plastics engineering program at Wisconsin’s Polytechnic University delivered, giving her lab experiences that included designing an injection mold in her molding class and then creating that mold in her machining class. This end-to-end experience on industry standard equipment in 91��Ƭ’s labs honed talents that Santelman applied in two internships, one of which led to a full-time job as a project engineer for Nolato, a plastics manufacturer in Baldwin.

“These internships helped me to understand the whole process that goes into manufacturing parts by seeing all sides of the process and documentation,” she said.

Santelman was also a two-sport athlete, playing on the Wisconsin Intercollegiate Athletic Conference conference-winning women’s golf team and as well as the women’s flag football team, which won the inaugural Midwest College Women’s Flag Football League Championship in 2025.

Santelman was among more than 1,000 Blue Devils who received their degrees at the university’s May 16 commencement ceremonies. Now as she begins her professional career, Santelman hopes she can bring new insights into the industry and advance her chosen field thanks to the personal and professional skills she developed at 91��Ƭ.

Cassie Santelman in the plastics engineering lab.

How has 91��Ƭ prepared you to work in your field?

91��Ƭ prepared me to work in my field by having industry grade machines to learn on, so I had experience with the equipment that I am working with in industry. My favorite lab experience would be designing an injection mold in my molding class and then getting to machine it in the machining class.

Where did you complete your internships?

My first internship was with Stratasys in Eden Prairie, Minnesota, as a quality engineer. I learned what goes into maintaining the quality of products and materials in an ISO 9001 facility. My second internship was with Nolato as a process technician, where I was on the floor learning how the company works from the production level. These internships helped me understand the whole process that goes into manufacturing parts by seeing all sides of the process and documentation.

Cassie Santelman, fifth from left in back row, celebrates with fellow members of the 91��Ƭ women's golf team after winning the WIAC Championship in October 2025. / Photo by Steve Frommell / D3photography.com

What stands out about your 91��Ƭ experience?

I love how small the class sizes are, which allowed me to build relationships with my professors and classmates. This helped me to feel more confident in asking for help as well as helping others when we got confused in classes.

Cassie Santelman with the trophy after 91��Ƭ won the first-ever Midwest College Women's Flag Football League Championship.

How did your involvement on campus impact your experience?

I am involved in three clubs: the Society of Women Engineers, where I was treasurer; the Society of Manufacturing Engineers, where I was also treasurer; and The Society of Plastics Engineers. I am also a member of the women’s golf team and the women’s flag football team. Being so heavily involved around campus has greatly impacted my experience by increasing my network between classmates and industry professionals.

What challenges did you face in earning your degree, and how did you overcome them?

I faced challenges balancing school and athletics being in two sports, but the small class sizes helped me get individualized help from my professors to stay on top of all my classwork while also excelling athletically.

What are you most proud of as you finish your degree?

I am most proud of graduating my degree as a scholar athlete and conference champion, proving that academics and athletics can go hand in hand without hindering one another.

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Hired before graduation at Redpath and Company as a tax associate

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Hired before graduation at Absolut Manufacturing

Hired before graduation as a process engineer at Nolato Inspiring Graduate Cassie Santelman receives diploma from Chancellor Katherine Frank

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Inspiring Graduate: Makenna Lowell, B.S. Packaging

giffeyt — Thu, 21 May 2026 15:30:00 +0000

Inspiring Graduate: Makenna Lowell, B.S. Packaging giffeyt May 21, 2026

Hired before graduation at Midwest Packaging and Container

Inspiring Graduate: Makenna Lowell (’26)

Hometown: Frederick, Maryland
Degree: B.S. Packaging
Minors: Sustainability

When it came to choosing a path after high school, Makenna Lowell knew exactly what degree she wanted to get and where she wanted to get it. As a student fascinated by both engineering and art, “Packaging felt like the perfect blend of those two passions,” Lowell said.

After learning about the packaging field during her older brother’s college search, Lowell was drawn to the packaging program at 91��Ƭ, one of the few U.S. universities to offer a packaging major. Lowell appreciated the fact that 91��Ƭ’s packaging program was part of the Robert F. Cervenka School of Engineering, which gave her an opportunity to take engineering-focused prerequisites.

Furthermore, 91��Ƭ’s status as Wisconsin’s Polytechnic University meant that Lowell could work with industry-standard equipment in on-campus labs while also pursuing off-campus cooperative opportunities within industry. Lowell applied her knowledge during co-ops at Kimberly-Clark and Ocean Spray Cranberries, in the latter instance completing a project that saved the company a projected $200,000.

Lowell was one of 1,067 Blue Devils who received degrees during the May 16 spring commencement ceremonies. Of this year’s graduates, 77.4% were hired prior to graduation, a group that includes Lowell: She’ll soon begin her career as a structural designer at Midwest Packaging and Container in Rockford, Illinois.

Outside the classroom, Lowell was both a leader in the Student Packaging Association and a campus tour guide with the Admissions Office. “Not only did I get to meet many great people, but the role significantly strengthened my public speaking, communication and time-management skills,” she said. “I always appreciated being treated as a student first, and the Admissions team was incredibly understanding and supportive of my academic schedule.”

What brought you to 91��Ƭ?

In high school, I loved both engineering and art. I completed the pre-engineering program and took ceramics, graphic design and other creative courses. Packaging felt like the perfect blend of those two passions. After researching the handful of universities that offer packaging programs, I toured several and ultimately chose 91��Ƭ for a few key reasons. The first is that the packaging program is housed under the School of Engineering, allowing me to take engineering-focused general education courses. Second, I liked Stout’s polytechnic focus and hands-on learning style. Third, I liked the mid-size of Stout because I didn’t want to be just another number. I love that I know most of the people in my major and I can build meaningful relationships with my professors.

How do you hope to make an impact in your field?

Sustainability has always been my driving force. I only wanted to enter the packaging industry if I could help make it more sustainable, and I hope to continue pushing the field toward environmentally responsible solutions.

How has 91��Ƭ prepared you to work in your field?

Stout’s polytechnic approach has been invaluable. I’ve gained hands-on experience with packaging equipment, testing methods and design software. Beyond coursework, Stout encouraged me to get involved. I’ve been a tour guide, lab tech, teaching assistant and president of our industry-affiliated Stout Packaging Association student organization. I’ve also attended numerous industry events, which significantly expanded my professional network.

What were the greatest lessons or projects you were involved in during your co-ops at Kimberly-Clark and Ocean Spray?

My first co-op was at Kimberly-Clark in Neenah, working on their baby and childcare team as a packaging engineering intern. I worked on optimization projects, competitor analysis, distribution testing and more. It was my first industry experience, and it helped me connect classroom concepts to real-world applications.

My second packaging engineering co-op in the food packaging industry was at Ocean Spray Cranberries in Lakeville, Massachusetts. One of my favorite projects was leading a new supplier qualification for paperboard cartons. I planned the trial, attended it independently, and validated a new carton that contributed roughly $200,000 in projected annual savings. My biggest takeaway was the importance of clear communication both across departments and with external partners.

What stands out about your 91��Ƭ experience?

What stands out to me about my 91��Ƭ experience is my packaging professors and labs. Because the program is small, the professors are deeply invested in our success. They’ve supported me at every step, inside and outside the classroom.

The labs have also been incredibly valuable. I’ve worked with nearly all the equipment, including manufacturing machines, material testers, and distribution testers, which has prepared me well for full-time work.

Packaging program to host international student-led Pack Jam conference

Pack Jam invites industry, alumni, community to see fresh ideas April 7-9

Were you involved in any clubs or organizations? How did your involvement impact your experience?

I was heavily involved in the Stout Packaging Association, our student-led, industry-affiliated club. From sophomore year through my fifth year, I served on the executive board, eventually becoming president. This involvement allowed me to attend industry events across the country, grow my network and meeting incredible people.

I’m also grateful for the Stout Foundation Scholarships and multiple industry scholarships I received. Their support motivated me to keep striving for excellence.

What are you most proud of as you finish your degree?

I’m most proud of the community I’ve built. From packaging peers and professors to industry professionals, tour guides, roommates, and friends, I’ve surrounded myself with people who have shaped my college experience in ways I never expected, in a place I never expected to be.

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Inspiring Graduates Share Their 91��Ƭ Polytechnic Experiences

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Hired before graduation at Redpath and Company as a tax associate

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Hired before graduation at Absolut Manufacturing

Hired before graduation at Midwest Packaging and Container Inspiring Graduate Makenna Lowell receives diploma from Chancellor Katherine Frank

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Our B.S. Packaging program provides hands-on training in package printing and design, business, quality management, and research and development.

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Distinguished alum, educator Albrecht credits 91��Ƭ for preparing graduates who ‘step forward’

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Co-op Q&A: Noah Klenner, Nicolet Plastics and Harley-Davidson

goersab — Tue, 12 May 2026 18:45:00 +0000

Co-op Q&A: Noah Klenner, Nicolet Plastics and Harley-Davidsongoersab May 12, 2026

‘My internships built on the strong foundation Stout has given me by showing me how concepts are used in actual production environments.’

For more than 120 years, Harley-Davidson, headquartered in Milwaukee, has been one of the world’s most recognizable motorcycle brands. Dominating the U.S. market, the heavyweight motorcycles and the signature orange and black shield embody the freedom of the open road.

Just a short ride up the shores of Lake Michigan is Nicolet Plastics, with facilities in Jackson and Mountain, Wisconsin. The custom injection molding company specializes in producing complex plastic parts for industrial, medical and consumer markets. It was recently awarded the Small Business Wisconsin Manufacturer of the Year Award.

Noah Klenner, a dual major in plastics engineering and mechanical engineering, completed two internships this year, one with each of these manufacturers.

“I most enjoyed seeing what it’s like to work in an engineering environment at both a smaller-scale company and a larger, more well-known manufacturing plant. I have a better understanding of how different teams operate, how communication and responsibilities vary, and how engineering work changes depending on the size and structure of the company,” Klenner said.

Klenner, of Slinger, was one of 24 91��Ƭ students who received the university’s 2026 Outstanding Cooperative Education and Internship Program Student of the Year Award. He will graduate in fall 2028 and is looking to start a role in manufacturing or process engineering, “ideally in an environment where I can continue working on product development, process improvement, and production optimization,” he said.

What were your main roles and projects at Nicolet Plastics?

At Nicolet Plastics, my first internship, was my first real-world engineering role working with injection molding machines in a manufacturing setting. As a plastics engineering intern, I worked closely with the processing team lead on injection molding process support, including helping with mold changes, machine start-ups, and adjusting processing parameters, like injection speed and temperature, to improve part quality and consistency.

Toward the end of this internship, I also helped gather data for production part approval process (PPAP) documentation. Much of my work involved monitoring and adjusting processing parameters, such as injection speed and temperature, to improve part quality and consistency. I also spent time on the production floor troubleshooting issues and working with the team to reduce defects and improve overall efficiency.

What were your main roles and projects at Harley-Davidson?

At Harley-Davidson, as an advanced manufacturing engineering intern, I worked with the new product development group, supporting new parts as they were being prepared for production. One of the main things I worked on was supporting validation efforts for new 2026 police motorcycle parts. A big part of my role was running and supporting validation testing, including ensuring cosmetic quality standards were met and helping with significant production runs (SPRs) to validate that parts and processes were capable of running at production scale.

Toward the end of this internship, I also helped create PPAP documentation for those same parts to support the production approval process. Overall, I was helping make sure parts met quality and production requirements before launch.

What was challenging about your internship, and how did you face those challenges?

One of the most challenging parts was dealing with process issues on the production floor, where there isn’t always a clear or immediate answer. In those situations, I learned to stay organized, ask the right questions, and work closely with experienced operators and engineers to narrow down the root cause. I also found that being patient and methodical, instead of rushing to a fix, made a big difference in solving problems effectively.

How will your courses and experiences at Stout help you make an impact in your career?

My coursework at Stout has given me a strong foundation in manufacturing processes, materials and engineering problem-solving. Hands-on lab work and project-based courses have been especially valuable because they connect theory to real-world applications.

My internships at Nicolet Plastics and Harley-Davidson really built on that by showing me how those concepts are used in actual production environments.

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‘My internships built on the strong foundation Stout has given me by showing me how concepts are used in actual production environments.’ Noah Klenner, CEIP award winner

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Career Services’ annual First Destination Report declared that 99.5% of recent plastics engineering and mechanical engineering graduates are employed or furthering their education within six months of graduation, with an average starting salary of $71,500.

This past year, more than 980 students participated in co-ops and internships through Career Services at nearly 600 employers in 28 states and three international locations.

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Engineering seniors design portable toy tractor manufacturing machine to engage kids in making process

goersab — Tue, 05 May 2026 13:45:00 +0000

Engineering seniors design portable toy tractor manufacturing machine to engage kids in making processgoersab May 5, 2026

Capstone concludes three-year professorship, collaboration with Urban Forestry Board

Abbey Goers

While Wisconsin farmers are out in their tractors preparing their fields, engineering students at 91��Ƭ have designed a portable manufacturing cell – a semi-automated assembly machine – to produce wooden toy tractors for area children.

The cross-disciplinary Taft Wooden Toy Assembly System group is made of five mechanical engineering and manufacturing engineering seniors: Owen Coon, of Appleton; Ben Gurka, of Beloit; Kierce Hemauer, of Menomonie; Ryan Kahl, of Menomonie; Aili Klein, of Lakeville, Minnesota; and Dominick Widi, of Stillwater, Minnesota.

Owen Coon, Kierce Hemauer, Ben Gurka, Aili Klein, Ryan Kahl and Dominick Widi

The two-semester-long project concluded their Engineering Technology Capstone 2 course, under the guidance of Assistant Professor Kevin Dietsche. The manufacturing cell is 40 inches wide, 38 inches long and 36 inches tall. Its height makes it accessible to elementary children, as Dietsche plans to transport the machine to area schools to demonstrate the toy manufacturing process. He can also show the cell on campus tours and at industry conferences. The machine is fully enclosed with safety features, allowing Dietsche to pause assembly and talk about the process.

Constructed to be able to fit in the back of Dietsche’s minivan, the two-part portable cell can be easily assembled and disassembled by one person, and its lightweight aluminum extrusion and plexiglass frame meets OSHA’s standards for a two-person lift. It can produce 20 tractors in an hour, including the main body, front and back wheels, and two dowel axles.

On May 1, the group showcased their system to engineering and technology faculty, as well as retired faculty members John Schultz and Professor Emeritus Jerome Johnson and City of Menomonie representative Megan Hines, environmental program coordinator with the Urban Forestry Board.

They presented again on May 4 to faculty, peers, industry partners, family and community members as part of the Senior Design Experience, which blends the university’s polytechnic tenets of applied learning and research, business and industry collaboration, and career-focused experiences.

The wooden toys, ducks and tractors are constructed from ash tree lumber provided by the City of Menomonie’s Urban Forestry Board.

An interactive toy manufacturing experience for kids

Challenges for the Taft Wooden Toy Assembly System group began on day one, as they essentially needed to redesign the previous group’s manufacturing cell from scratch. The previous design had broken and was not usable for testing.

However, this also gave them the opportunity to revamp the design in their own way. Their concept ideas in CAD included updating the sheet metal frame to a stronger aluminum extrusion and plexiglass frame. This was also a durability and safety consideration. The original sheet metal frame had sharp corners and was not as solid – features the group deemed unsafe, since the machine is meant to be accessible to children.

With Dietsche as their project sponsor, the group’s lead capstone instructors were Assistant Professor Nathan Spike and Senior Lecturer Glenn Bushendorf, to whom they presented their initial research and design concept for critique. The group was aided by Instrumentation Coordinator-Instructor Paul Craig and Lecturer Brandon Dick for coding and controls and Lecturer Mike Miller with sensors.

“The build phase brings a spark to see the fully functional machine. Our overall design has changed a lot. It’s two inches bigger and wider than our initial concept. The cell originally had seven doors, but after talking with Paul, we changed it to have one plated door on top. This cut down on the number of safety latches that we needed,” Hemauer said. “The machine also has an emergency stop button, and if the door is opened during production, the machine will stop.”

The wooden tractor components are fed by Dietsche through the top door into 3D-printed gravity-fed chutes. Then, like a mini-Henry Ford assembly line, five actuators – one for the body and one for each wheel – feed the components through the machine.

At first, the group designed the machine to be automated. “But we switched to have the dowels be manually inserted through the wheels, so kids can engage in the making process,” Klein said. “We also included a human-machine interface (HMI) touch screen for kids to give them an industrial feel. The screen shows images to guide kids through the steps of making the tractor.”

It was Hemauer’s idea of a Pez dispenser that evolved into the bolt-action idea of the manual insertion of the dowels, similar to how a ball is launched in a pinball machine. The insertion of the dowels is a press-fit operation, with no glue involved.

In their research, the group found that the pull force of a 6- to 10-year-old child is 22 pounds. They made the pull factor of the wheels 60 pounds for added safety and durability, knowing children would try to remove the wheels. They also imagined children would attempt to sit on and ride the tractor, although it is only 6 inches long and 3 inches high. With extra-strong dowels, made of oak, and chamfered wheels for structural integrity, the tractor can support up to 200 pounds.

A controls box mounted on the front of the machine houses the circuit board. They also added a plaque commemorating the professorship project, as well as ash wood brackets to cover the metal brackets on the exterior casing, giving the machine a warmer appearance.

The group enjoyed the cross-disciplinary project and understands the importance of the experience as they prepare to graduate and enter the workforce. “Working across majors helps you see other people’s point of view and their strengths,” Gurka said. “We’re building communication skills and the confidence to ask each other questions. It’s being able to admit when you don’t know something and being able to fall back on each other for knowledge.”

A collaboration connecting people to people

The project concludes Dietsche’s three-year G.A. Taft Manufacturing Engineering Endowed Professorship, in which various groups of students designed toys with first-graders, created AI rapid prototypes of toys with kindergartners and built a two-wheel toy assembly system to produce a wooden duck, including its body, wings, wheels and dowel axle.

Professor Emeritus Jerome Johnson gives a brief history of the collaboration during the capstone presentation.

The collaboration between the engineering and technology department and the city’s Urban Forestry Board began nearly a decade ago with the support of a Wisconsin Department of Natural Resources grant. As the city’s ash trees were dying and trees were being cut down, the grant funded the cutting, acquiring, milling, and kiln-drying of the ash wood. The repurposed wood was then used in student projects, creating benches for the City of Menomonie parks.

The projects were fostered under the guidance of Johnson and Nancy Schofield, a former 91��Ƭ professor and member of the Urban Forestry Board, who has since passed.

“Students wanted to see something that they built be used out in the city. Students became leaders and produced projects I never imagined possible,” said Johnson, who was honored as Citizen of the Year by the Menomonie Urban Forestry Board in 2021.

Professor Kevin Dietsche presents Environmental Program Coordinator Megan Hines with a toy wooden tractor and duck.

Students produced more than 20 city benches from the repurposed ash wood between 2018 and 2021, when Johnson retired and Dietsche stepped in to take his place. “This project has impacted how I teach. It follows a high-impact practices model (HIPS), which reinforces the importance of partnerships and hands-on activities, creating a whole team of student leaders,” Dietsche said.

“This project is something special. We’re able to take something dead and dying and give back to the city, with an end goal of showing kids the engineering process – from mechanical and technical to packaging. The real key is connecting people to people,” he added.

Dietsche plans to continue similar projects with the addition of artificial intelligence and circular design practices in the research and development, as well as construction and repair processes.

Graduates from 91��Ƭ’s mechanical and manufacturing engineering programs reported 99.5% employment rate within six months of graduation and an average starting salary of more than $70,000, according to the latest university First Destination Report.

91��Ƭ’s Robert F. Cervenka School of Engineering is home to five ABET-accredited programs that also include computer and electrical engineering, engineering technology and plastics engineering, as well as a sixth bachelor’s program in packaging. A master’s in manufacturing engineering is available on campus or online.

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Music to honor a master: Ukulele kits by engineering students are in homage to alum Kuboyama

goersab — Mon, 13 Apr 2026 15:34:32 +0000

Music to honor a master: Ukulele kits by engineering students are in homage to alum Kuboyamagoersab April 13, 2026

Cross-disciplinary groups also design toolless furniture connections, learn valuable customer perceptions

Abbey Goers

A small black case rests atop a filing cabinet in Assistant Professor Kevin Dietsche’s office. He opens the case and begins strumming a ukulele. The soft music fills the office. Dietsche, an engineering technology instructor at 91��Ƭ, built the ukulele 15 years ago under the guidance of Kazukiyo “Jiggs” Kuboyama, a master in his craft who was honored by the Ukulele Guild of Hawaii.

In homage to Kuboyama, Dietsche tasked his own students to develop a process to build ukuleles in his New Product Development course this semester. “For me to do this is in honor of his tradition,” Dietsche said of Kuboyama, who was a 1957 91��Ƭ industrial arts alum. He taught technology education in Oahu and passed away in 2019.

Professor Kevin Dietsche and Braden Kapitz watch as the CNC machine removes wood to shape a main ukulele jig.

The project grew to also include developing toolless bed connections, with one group expanding their design to work across different furniture types – a solution allowing for flexibility of use.

The engineering technology and mechanical engineering students worked in cross-disciplinary groups to research market trends and materials and to ideate preliminary designs before they were joined by engineers and designers from Ashley Furniture Industries, including industrial and product design alums Caleb Toft and Anna Lindner, as well as Emeritus Professor Jerome Johnson, who viewed the groups’ design presentations and provided insight based on their industry experience.

The groups then began their build process of the ukuleles and toolless connections in the Jarvis Hall Technology Wing Woods Lab.

“These projects are about teaching the students problem solving through the design process. The most difficult part is getting your first draft right. Once you’ve troubleshooted everything, you can build hundreds of models using your programming,” Dietsche said.

Creating ukulele building kits for beginners

The ukulele groups are meeting the challenge of making instrument-building kits more accessible to beginners. Two groups – Andrea Smith, of East Troy, and Brook Derks, of River Falls; and Konnor Kraft, of Plymouth, Minnesota, Alex Ogno, of DeForest, and Braden Kapitz, of Athens – researched ukulele construction methods, dimensions, and kerfing techniques, and how wood type and body shape affects sound quality and buildability.

Konnor Kraft shows a cardboard prototype and a CNCed jig for a ukulele.

“Traditional instrument construction requires a high level of craftsmanship, which can be difficult for those with limited woodworking experience. Our goal is to simplify the process so anyone can successfully build a ukulele using guided methods and fixtures,” Smith said.

The groups designed main jig blocks in SolidWorks to match the size and shape of a ukulele and then, using AI contour construction, they removed the inner material on a CNC machine to make the manufacturing process more consistent and repeatable.

Andrea Smith and Brook Derks discuss their ukulele design.

“We then steamed .08-inch-thick strips of ash wood for 45 minutes to make it malleable and clamped it to the inside of the main jig block for 48 hours to create the exterior curve of the instrument,” Kraft said. “The quality of the wood can affect how it curves, as well as how long it is steamed. We found that 45 minutes in the steamer was optimal for malleability, and that knots will affect the wood’s strength. It will weaken and split at the knot when curved.”

The groups also made kerfing supports (flexible, notched wooden strips glued to the inside of the ukulele body to strengthen the structure). “The top of our ukulele will be made of spruce for sound quality and the neck will be made of cherry wood for its vibrant color,” Kraft said.

Konnor Kraft cuts pieces for a ukulele neck on a bandsaw, assisted by TA Annika Schlueter.

Smith and Derks expect bending the wood sides and achieving consistent kerf cuts to be challenging, since both directly affect the shape and structural integrity of the ukulele. “Designing jigs that ensure accurate alignment and repeatability has also required careful planning. We’re looking forward to testing to see how well our designs perform and what adjustments may be needed,” Smith said.

She’s enjoyed researching everything that goes into making a ukulele and understanding how each component affects the final instrument. “It’s been especially rewarding to take that knowledge and apply my design skills to create something that actually works. Seeing the transition from research to a functional build has been the most satisfying part of the process,” Smith said.

Andrea Smith and Brook Derks ready their ukulele jig block for the CNC machine.

Simple, functional, attractive and mass-manufacturable designs

One of the toolless connections groups – Alex Dill, of Hartland, Aden Story, of Holcombe, and Bethany Winge, of Cottage Grove – first worked to identify ways that toolless assembly works in conjunction with a flatpack bed frame (a bed designed to be deconstructed into individual components). They then compared their drafted ideas to existing market solutions.

“We found that a flatpack frequently involves various methods that have self-aligning or self-maintaining joinery. From there, we began to brainstorm connection methods that involved self-contained components, or single-step customer assembly and disassembly items,” Dill said.

TA Annika Schlueter and Bethany Winge construct a frame for an epoxy mold pour.

From Toft and Johnson’s critiques, the group thought the most interesting was to remember how material affects customer perception and quality of an item. “For example, a nicely finished piece of stainless steel has a much more premium feel than injection molded plastic,” Dill said.

Dietsche required the toolless connection groups to produce their designs with three different manufacturing methods and materials. Dill, Story, and Winge’s thumbscrew and locking head device is intended to work across different furniture types.

Their methods and materials include: 1.) a 3D-printed component, designed in SolidWorks and printed by Story on his home 3D printer; 2.) a poured epoxy component, produced using a two-part casting rubber mix; and 3.) a metal component, based on availability and machinability, such as stainless steel and aluminum, and cut out by Dill on the CNC machine in the Machine and Subtractive Processing Lab in Fryklund Hall.

TA Annika Schlueter and Bethany Winge mix the two-part casting rubber for an epoxy mold pour.

“The epoxy pour makes everything more repeatable in the manufacturing process. And our 3D-printed component is very well designed and thought out. But I think the metal component would sell the best in the real world,” Winge said.

The challenging part is almost always coming up with a design, as it needs to be simple, functional, attractive, and most importantly, mass manufacturable, Dill said. “Professor Dietsche facilitates a phenomenal environment to learn about CNC programming and other shop processes. Being able to go out in the lab and make things while learning how on the fly has proven very fun and interesting.

“More people should take technical manufacturing classes, as they build an appreciation for how the world around us is made,” he added.

Aden Story holds a 3D-printed thumbscrew for toolless furniture assembly.

91��Ƭ’s engineering and technology department offers six undergraduate degrees, including computer and electrical engineering, manufacturing engineering, mechanical engineering, plastics engineering, engineering technology and packaging, as well as four minors and a master’s in manufacturing engineering.

Technology education is offered through the School of Education, which is home to nine undergraduate degrees, five graduate degrees, certificates, certifications and online professional development courses.

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Kevin Dietsche

Teaching Interests: Joining, Foundry, Fluid Power, Mechatronics

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John Deere partners with engineering students, faculty on sustainable plastic research

giffeyt — Thu, 09 Apr 2026 13:00:00 +0000

John Deere partners with engineering students, faculty on sustainable plastic researchgiffeyt April 9, 2026

Two-year project seeks to identify recycled polymers that can be used in manufacturing process

Tom Giffey

John Deere machinery has been recognizable for its distinctive green color for more than a century. Student and faculty researchers at 91��Ƭ are working to ensure that John Deere is also known for a different kind of green: sustainability.

Led by Professor Wei Zheng, student research assistants in the B.S. plastics engineering program have been working over the past two academic years to study how John Deere might be able to use recycled plastic polymers to manufacture vehicles.

Zheng is an active member of the Society of Plastics Engineers, and it was through that organization that she formed connections with engineers from John Deere, which is based in Moline, Illinois. The relationship led to a research contract between the Fortune 500 company and 91��Ƭ, which was facilitated by the university’s Office of Corporate Relations & Economic Engagement.

Beginning in August 2024, students and faculty have tested and molded batches of different types of recycled plastic to see if they meet the manufacturer’s needs.

“John Deere is asking two key questions,” Zheng said. “Can recycled polymers be used to manufacture these parts? And can those parts meet performance requirements?”

The research is part of the company’s commitment to incorporating more recyclable and renewable materials into its products so it can be ahead of the curve in its industry, she said.

Student research assistant Ryan Xu measures plastic samples.

Students create, test samples

This semester, two student research assistants have worked on the project. One of them, junior Stephanie Kuhn, explained that the process begins with pellets of different types of recycled plastic polymer that are fed into a massive injection molding machine in the Plastics Engineering Lab inside Jarvis Hall Technology Wing.

Heat and friction melt the pellets, which are forced into a mold where they take the desired shape. Once completed, these pieces are cut precisely into various testing specimens by Instrument Shop Supervisor John Buss, who also assists with machine-related issues.

Next, students subject the specimens to a range of tests, including evaluating their short- and long-term mechanical behavior under stress, as well as their thermal and physical properties to assess overall performance.

Kuhn, who is pursuing a double major in B.S. plastics engineering and B.S. mechanical engineering, said having an opportunity to do this kind of work as an undergraduate is what attracted her to 91��Ƭ.

“I just love being able to use all the machines hands-on. It helps being able to see and use the equipment,” Kuhn said. While already familiar with the injection units and testing equipment from her coursework, taking part in the research helped Kuhn better understand how the equipment operates, reinforcing what she learned.

Likewise, the importance of the research has been highlighted by Kuhn’s classwork, which has emphasized the need for increasing the use of recyclable plastics. “It has definitely opened my eyes that we need to learn to be more sustainable,” she said. “If John Deere begins to use this, hopefully other manufacturers will, too.”

Sabbatical recap: Wei Zheng, Plastics Engineering, 2024-25

Building biodegradable, sustainable plastics

This semester’s other research assistant, Ryan Xu, a Menomonie High School senior who is already taking classes at 91��Ƭ, said he appreciates the applied nature of the project, including being able to use advanced equipment and analyze data.

Professor Adam Kramschuster has also helped with the John Deere research project by setting up, optimizing and troubleshooting the injection molding process for manufacturing the samples. This work has involved training the student research assistants and helping with the machine during the molding trials.

“I love working with students. It’s why I am here, and I enjoy it when they learn and take responsibility as their knowledge base grows,” Kramschuster said.

“Our labs are exceptional,” he continued, “and the opportunity to use them for industry projects is ideal in that the students get even more real-world training during their undergraduate experience.”

Student research assistants Ryan Xu, left, and Stephanie Kuhn work with an injection molding machine in 91��Ƭ's Plastics Engineering Lab.

Sustainability key to professor’s research

The kind of research happening in the Plastics Engineering Lab isn’t uncommon at 91��Ƭ. In fact, applied learning and research are among the pillars of the university’s polytechnic identity, which also include business and industry collaboration and career-focused experience – all three of which are part of the John Deere project.

Zheng noted that two of her prior research assistants leveraged their experience on the project to find jobs in the plastics industry at EVCO and Phillips Medisize. “This project helped them to solidify their injection molding and material testing skills, giving them a clear advantage in the job market,” she said.

The research, she added, will continue through at least this August. “John Deere is quite pleased with the results we have generated so far,” she said. “John Deere has been very supportive throughout the process, including providing Stout the plaque mold and materials, as well as sharing their technical expertise. They even connected us with material suppliers and molders.”

Zheng’s work on behalf of John Deere complements her ongoing research focus on sustainability. During the 2024-25 academic year, Zheng conducted sabbatical research in advancing sustainability in the field of plastics, focusing on the biodegradation of plastic materials and the recycling of thermosetting materials. Typically, thermoset plastics have undergone a curing process that prevents them from being remelted or reshaped, posing a challenge in the recycling process. However, plastics engineers and chemists researching the reverse crosslinking process are developing ways to break the chemical bonds, allowing thermosetting plastics to be recycled. Part of Zheng’s research focused on finding ways to reverse the process, increasing the recyclability of this kind of plastic.

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John Deere partners with engineering students, faculty on sustainable plastic research

Two-year project seeks to identify recycled polymers that can be used in manufacturing process

Two-year project seeks to identify recycled polymers that can be used in manufacturing process Plastics Lab Injection Molding Machine

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Hero Caption: Student research assistants Stephanie Kuhn, left, and Ryan Xu hold samples in front of an injection molding machine in 91��Ƭ's Plastics Engineering Lab.

Wei Zheng

Dr. Zheng is an Associate Professor and Program Director of the Plastics Engineering Program at University of Wisconsin-Stout. Prior to joining 91��Ƭ, she was a Postdoctoral Researcher in the Polymer Science and Engineering Department at University of Massachusetts-Amherst. She received a Ph.D. in Chemical Engineering from Texas Tech University in 2008. She is the recipient of several state-funded grants including the WiSys Applied Research Grant and the G. A. Taft Professorship of 91��Ƭ.

Her current research focuses on the bio- and/or biodegradable polymers including rheology of polymer melts and glasses, physics of crystallization and glass transition, curing kinetics of reversible thermosets, and structure-property-processing relationship. She has published 32 refereed articles with more than 700 citations. Dr. Zheng has also been active in the Society of Plastics Engineers (SPE) including serving as the Councilor of the Applied Rheology Division of SPE and the President of Chinese American Society of Plastics Engineers.

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