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1. Virtual Reality Education Modules for Digital Manufacturing Instruction

   Chandramouli, M.; Jin, G.; Heffron, J.; Cossette, M.; Fidan, I.; Merrell, W.; Welsch, C. (July 2018, ASEE Annual Conference proceedings)

   There is an imminent need to remedy the ‘skills gaps’ in the digital manufacturing (DM) sector as evident from the Bureau of Labor Statistics projections pointing to a decline in traditional manufacturing jobs accompanied by marked growth in digital- and computer-driven manufacturing jobs. With proven advantages such as cost benefits, material conservation, minimized labor, and enhanced precision, manufacturing industries worldwide are adapting to digital manufacturing standards on a large scale. In an effort to remedy the lack of well-defined DM career pathways and instructional framework, our NSF ATE (Advanced Technological Education) project MANEUVER (Manufacturing Education Using Virtual Environment Resources) is developing an innovative pedagogical approach using virtual reality (VR). This multimodal VR framework DM instruction targeted at 2-year and 4-year manufacturing programs, facilitates the development of VR modules for multiple modes such as desktop VR, Augmented VR, and Immersive VR. The advantages of the virtual reality framework for digital manufacturing education include: significant cost reduction, reduction in equipment and maintenance costs, ability to pre-visualize the product before manufacturing. This paper introduces the design and development process of VR education tool to simulate three different additive manufacturing machines, e.g., LutzBot™, FormLabs™, and UPrint™ and different 3D printing technologies e.g., fused deposition modeling, and selective laser sintering to allow the students experience the materials and equipment needed to create the same part using different types of equipment and different types of technology. 

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2. The Mini-Mill Experience: A Self-Paced Introductory Machining Exercise for Mechanical Engineering Students

   https://doi.org/10.18260/1-2--48122  

   Buckley, Jenni; Trauth, Amy; De_Rosa, Alexander (June 2024, ASEE Conferences)

   Practicing mechanical engineers interface regularly with machinists to design and manufacture components in metal and other engineered materials. Direct, hands-on exposure to precision machining operations, like mill and lathe work, helps young engineers design manufacturable components and facilitates better collaboration with machinists. Mechanical engineering undergraduate programs have been cited for weaknesses in training students on industry-standard manufacturing practices. While there are several excellent examples in the literature of student manufacturing projects, these projects are relatively advanced on the whole, and they require extensive human and capital resources to deploy in large-enrollment classes. Prior investigators have conserved resources by teaming students on projects, which dilutes the hands-on manufacturing experience for individual learners. In this study, we present an introductory mill training exercise for engineering students that allows them to individually develop transferable machining skills but requires fairly modest resources. This exercise, which we call the “Mini-Mill Experience,” involves students individually manufacturing two separate parts with a hobby-grade mini-mill and then completing a written self-reflection documenting their procedures and final part inspection. Students first manufacture a simple part out of reusable wax with direct coaching from a teaching assistant. They then independently manufacture one of six different wooden Erector Set components. The Mini-Mill Experience is designed to give students firsthand experience and promote confidence with the basic mill controls and operations, e.g., changing out an endmill or squaring up a face, that are transferable to the full-sized mills they will use in later courses. The one-time equipment set-up costs for this exercise were approximately $60 per student, with recurring costs of less than $2 per student for stock material. Each student completed the exercise during a two-hour lab period, and it took approximately six weeks for all students in the course (ca. 170 students) to complete the exercise. All sessions were supervised by a machinist and one to two teaching assistants. To gauge the effectiveness of the Mini-Mill Experience, a survey was distributed to all students in a freshmen year mechanical engineering design course. Survey responses indicated that the majority of the students (77%) had no prior experience with mills. Post-activity, students reported high levels of self-confidence in identifying the critical components of a mill and most basic mill operations, like proper use of a vise and tool changes. Compared to students who had prior mill experience, students with no prior experience demonstrated slightly lower self-efficacy with more advanced mill operations like creating blind holes and tapping threads. Post-activity, 75% of students agreed they “were not intimidated or afraid to use the mill to make a part,” and 90% said that they “looked forward to their next experience on a mill.” In this study, we developed an introductory manufacturing experience – the “Mini-Mill Experience” – that is effective in teaching basic mill operations, promotes students’ self-efficacy and enthusiasm for future machining experiences, and is cost effective and scalable for large class sizes. In these ways, it is a valuable addition to the existing literature and curriculum on manufacturing education for mechanical engineers. Future work by our group will focus on whether the skills acquired in the Mini-Mill Experience are transferable to manufacturing experiences later in the curriculum. 

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3. Use of Virtual Reality to Improve Engagement and Self-Efficacy in Architectural Engineering Disciplines

   https://doi.org/10.1109/FIE49875.2021.9637182  

   Erdogmus, Ece; Ryherd, Erica; Diefes-Dux, Heidi A.; Armwood-Gordon, Catherine (October 2021, Use of Virtual Reality to Improve Engagement and Self-Efficacy in Architectural Engineering Disciplines)

   This Innovative Practice Full Paper presents findings from the implementation of a virtual reality-based learning module. In the Fall of 2020, a prototype for a novel intervention namely, Virtual/Augmented-Reality-Based Discipline Exploration Rotations (VADERs), was offered as part of the first-year Introduction to Architectural Engineering (AE) classes at two universities. VADERs will ultimately be a collection of modules that are designed to improve student engagement and diversity-awareness by providing interactive virtual explorations of an engineering discipline and its sub-disciplines. VADERs utilize an open source, device-agnostic, and browser-based three-dimensional Virtual Reality (VR) platform, creating unique accessibility, synchronous social affordances, and media asset flexibility. The conjecture explored in this paper is: Having first-year engineering students experience Architectural Engineering and its sub-disciplines through an interactive VADER module, will improve their self-efficacy in regards to their commitment to studying the discipline. A total of 89 students participated in the VADER pilot in Fall 2020. Complete data was collected from 67 of these participants in the form of pre- and post- surveys, and final project deliverables. Results tied to the hypothesis and recommendations for future related work are discussed. 

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4. Eye-Track Modeling of Problem-Solving in Virtual Manufacturing Environments

   Zhu, Rui; Aqlan, Faisal; Zhao, Richard; Yang, Hui (July 2021, ASEE annual conference proceedings)

   null (Ed.)

   Problem-solving focuses on defining and analyzing problems, then finding viable solutions through an iterative process that requires brainstorming and understanding of what is known and what is unknown in the problem space. With rapid changes of economic landscape in the United States, new types of jobs emerge when new industries are created. Employers report that problem-solving is the most important skill they are looking for in job applicants. However, there are major concerns about the lack of problem-solving skills in engineering students. This lack of problem-solving skills calls for an approach to measure and enhance these skills. In this research, we propose to understand and improve problem-solving skills in engineering education by integrating eye-tracking sensing with virtual reality (VR) manufacturing. First, we simulate a manufacturing system in a VR game environment that we call a VR learning factory. The VR learning factory is built in the Unity game engine with the HTC Vive VR system for navigation and motion tracking. The headset is custom-fitted with Tobii eye-tracking technology, allowing the system to identify the coordinates and objects that a user is looking at, at any given time during the simulation. In the environment, engineering students can see through the headset a virtual manufacturing environment composed of a series of workstations and are able to interact with workpieces in the virtual environment. For example, a student can pick up virtual plastic bricks and assemble them together using the wireless controller in hand. Second, engineering students are asked to design and assemble car toys that satisfy predefined customer requirements while minimizing the total cost of production. Third, data-driven models are developed to analyze eye-movement patterns of engineering students. For instance, problem-solving skills are measured by the extent to which the eye-movement patterns of engineering students are similar to the pattern of a subject matter expert (SME), an ideal person who sets the expert criterion for the car toy assembly process. Benchmark experiments are conducted with a comprehensive measure of performance metrics such as cycle time, the number of station switches, weight, price, and quality of car toys. Experimental results show that eye-tracking modeling is efficient and effective to measure problem-solving skills of engineering students. The proposed VR learning factory was integrated into undergraduate manufacturing courses to enhance student learning and problem-solving skills. 

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5. Multiplayer Physical and Virtual Reality Games for Team-based Manufacturing Simulation

   Aqlan, F. (June 2020, ASEE Annual Conference proceedings)

   Familiarity with manufacturing environments is an essential aspect for many engineering students. However, such environments in real world often contain expensive equipment making them difficult to recreate in an educational setting. For this reason, simulated physical environments where the process is approximated using scaled-down representations are usually used in education. However, such physical simulations alone may not capture all the details of a real environment. Virtual reality (VR) technology nowadays allows for the creation of fully immersive environments, bringing simulations to the next level. Using rapidly advancing gaming technology, this research paper explores the applicability of creating multiplayer serious games for manufacturing simulation. First, we create and validate a hands-on activity that engages groups of students in the design and assembly of toy cars. Then, a corresponding multiplayer VR game is developed, which allows for the collaboration of multiple VR users in the same virtual environment. With a VR headset and proper infrastructure, a user can participate in a simulation game from any location. This paper explores whether multiplayer VR simulations could be used as an alternative to physical simulations. 

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