This week the FLARE team focused on final data analysis and project closeout. We completed analysis of our experimental results and used the data to refine both our sub-scale and full-scale models. Key performance metrics, including power-to-weight ratio, power density, and overall efficiency, were calculated for each system. Additional thermal FEA simulations were conducted to further validate temperature behavior at both scales. We also presented at the Final Design Review, where we showcased our results and demonstrated our fully integrated testing apparatus in the wind tunnel to our liaison, marking the conclusion of the project.

This week the FLARE team conducted final testing while addressing key technical challenges. During initial high-temperature testing, an issue with RTV sealant required adjustments to our thermocouple setup to ensure safe and reliable operation. Following this, we achieved stable temperatures around 240°C and continued collecting data for the full TEG system. In parallel, we finalized our 3D upscaled thermal model to predict performance at higher temperatures. With the Final Design Review approaching, the team also focused on completing deliverables and preparing for project closeout.

This week the FLARE team focused on integrating the testing setup into the wind tunnel and preparing for final data collection. We completed installation of the system and conducted initial heating tests to verify operation in the tunnel environment. During this process, we identified and worked through data collection challenges to ensure reliable measurements moving forward. In parallel, the team developed draft materials for the IPPD video and poster to clearly communicate our design and testing approach. We also began running final thermal simulations to support performance predictions and compare against upcoming experimental results.

The team successfully assembled the primary hardware prototype, including the base plate, CNC-machined top plate, and custom copper heat sinks. During Tuesday’s inspection, a live thermal demo confirmed the PID controller could maintain target temperatures. Bench testing showed the electrical junction box and 1800W heater array operated safely and as expected. A recommended dry run without TEG modules will help map heat distribution and avoid thermal overshoot. Remaining tasks include installing the four TEG modules, applying high-temperature thermal paste, and securing insulation. Instrumentation and thermocouple routing are also being finalized to ensure accurate data collection during high-speed tunnel testing.

This week the FLARE team made significant progress toward final system integration and testing readiness. The electrical box wiring was completed, enabling power regulation through the Raspberry Pi, with the system operating on a 20-amp circuit and 12-gauge wiring for safety. Additional safety features, including color-coded labeling and an indicator light, are being finalized. Due to ongoing machine shop issues, the top plate fabrication was outsourced to the IPPD CNC shop and is nearing completion.

In parallel, the team advanced control and analysis efforts by transitioning to a PID controller to improve temperature stability and integrating a data collection dashboard. Material analysis of the TEG modules was also completed using SEM and EDS techniques. Looking ahead, the team is preparing for Prototype Inspection Day with a controlled demonstration and plans to begin wind tunnel testing soon while lab availability is open.

This week the FLARE team completed several key steps toward final system assembly and testing readiness. The junction box was fully assembled, integrating the electrical components needed to control and power the heating cartridges. The heating cartridges were also tested using the completed junction box and successfully reached temperatures of 300 °C, confirming that the heating system can achieve the required thermal conditions for testing. Additionally, a previously broken tap was removed from the bottom aluminum plate, restoring the part to a usable condition for installation. The finalized CAD model and detailed drawings for the top plate were also sent to John, the IPPD CNC machinist, so that machining of the final component can begin.

This week the FLARE team encountered manufacturing delays due to equipment issues in the campus machine shop. The VF-3 CNC mill required for machining the top plate is currently out of service because of a broken spindle, temporarily halting final fabrication. To address this, the team began coordinating with the shop manager to explore alternative machining options, including using the VF-2 mill or gaining access to the IPPD CNC machine.

Despite the delay, progress continued on other fronts. The custom copper heat sinks and bottom aluminum plate have been fully machined, leaving only the top plate machining and heater cartridge hole reaming as the remaining fabrication steps. The team also planned a bench test to verify heating elements and PID control functionality before scheduling wind tunnel testing.

This week marked major progress in manufacturing and system integration. The bottom plate of the testing apparatus was fully machined and completed, and CNC tooling was developed for the top plate, which is scheduled to be machined shortly. We verified that the nominal heater sizing will fit properly in the top plate and finalized software for monitoring sensor data. Additionally, we successfully completed QRB 2 and received valuable feedback to guide our final testing phase.

Next week, we plan to fully assemble the mechanical components, begin electrical integration within the junction box, and test the relays to ensure reliable heater control.

This week centered on final assembly planning, electrical integration, and manufacturing coordination. CAD updates incorporated standoffs, fasteners, copper heat sinks, and finalized cable gland placement to manage approximately 25 system wires. The electrical configuration was refined, wiring four heaters in parallel to a 20-amp fuse and grounding the top plate for safety. Manufacturing plans were optimized to reduce CNC setup time, and heater hole verification will be completed before final machining. Additionally, we discussed using Reynolds and Prandtl numbers to non-dimensionally scale experimental results to real-world high-temperature applications.

This week focused on finalizing the heating solution and advancing the mechanical design toward manufacturing. The team refined the aluminum top plate design into a longer single-row configuration and completed the CAD model in preparation for CNC machining. Updates included improved insulation materials, mounting strategies, cable gland integration, and heater fit verification. Thermal FEA results showed safe operating temperatures for the wind tunnel interface. We also reviewed thermocouple setup plans and discussed scaling approaches for higher-temperature applications, ensuring both experimental readiness and alignment with full-scale modeling goals.