DAHLGREN, Va. –
The Virginia Tech Interdisciplinary Capstone (IDC) program is redefining how engineering students transition from theory to practice. Unlike traditional department-specific capstone courses, IDC integrates students from diverse disciplines, including mechanical engineering, electrical and computer engineering, systems engineering, materials science engineering and computer science. This collaborative approach prepares students for the challenges and opportunities they’ll face in their careers.
For the past three years, the IDC program has partnered with Naval Surface Warfare Center Dahlgren Division (NSWCDD), providing students with practical exposure to solving complex engineering problems. This partnership has brought together multidisciplinary teams from Virginia Tech and NSWCDD engineers and resulted in solutions for the Navy.
Aligning undergraduate research with Navy objectives
NSWCDD’s High Power Microwave (HPM) Weapon Systems Division specializes in developing electromagnetic weapon systems that disrupt or turn off electronics and other technologies. Reliability, precision and economic efficiency are at the core of the division’s mission to support warfighters. The partnership with Virginia Tech bridges academic capabilities with military needs, fostering a relationship between research and development.
“Our focus in the HPM Weapon Systems Division is to develop systems capable of disabling electronics and safeguarding warfighters,” said Alan Overby, electrical engineer and branch head at NSWCDD.
By exposing students to actual challenges – such as building test infrastructure for advanced military systems – future engineers gain insights into mission-driven projects while understanding the impact of supporting national defense efforts.
“This relationship is a win-win,” said Overby. “It supplies NSWCDD with fresh perspectives while exposing students to advanced engineering projects.”
It provides:
Hands-on experience: Students tackle engineering issues provided by NSWCDD, making immediate connections between academic learning and real-world applications.
Interdisciplinary collaboration: Imitating industry standards, students learn to work across disciplines and develop holistic solutions.
Impact on defense: The advancements developed during these capstone projects are not just academic exercises; they’re prepared for immediate use by NSWCDD engineers.
Pipeline development: For NSWCDD, the partnership prepares students to seamlessly integrate into defense industry teams.
The Outboard Motor Dynamometer project
A recent standout among these collaborative efforts is the Outboard Motor Dynamometer (OMD) project. Over two years, Virginia Tech teams have been tasked with creating a robust and efficient dynamometer system while reducing the complexity of traditional test setups. The system simulates realistic conditions to test the performance and reliability of outboard motors in a controlled environment.
Key stakeholders – including NSWCDD subject matter experts Overby, August Valentour (both Virginia Tech graduates), Adam Suleske, Joel Mejeur and Amy Meyer, alongside student teams led by Virginia Tech faculty advisor and professor Robin Ott – worked closely to refine the dynamometer into a more effective and adaptable solution. At the heart of the project lies the goal of engineering a smarter and more cost-efficient approach for testing naval systems.
“Last year’s student team laid the groundwork, conceptualizing a system that uses eddy current braking – brakes that rely on electromagnetism to stop objects from moving – for energy dissipation,” said Overby. “This year, the new team not only refined the design but incorporated entirely new features to improve adaptability, variability and operational safety.”
Adaptability: Students designed an innovative hub adapter to work with varying outboard motor configurations. This adapter ensures compatibility across different systems.
Variability: A pneumatic control system, operated by air under pressure, allowed precise adjustments to the air gap between the dynamometer’s rotor and stator, leading to the optimization of power and torque dissipation. This improvement enabled control and energy efficiency during testing.
Cost-Effectiveness: By leveraging clever material use and modular design, students delivered a high-quality solution for under $5,000, drastically reducing costs compared to commercially available options, which typically range from $30,000 to $50,000.
Navigating difficulties and learning through experience
The dynamometer project had its ups and downs.
“The biggest challenge was getting the control system to function,” said Matt Barnett, one of the senior design team members.
It took some time for Barnett and the team to establish communication between the Raspberry Pi and the automatic transducer – a device that converts a physical quantity into an electrical signal that can be measured – a task they hadn’t anticipated.
Early tests on the updated system also produced surprising results; the copper rotor performed worse than projected. This called for reevaluation.
With guidance from NSWCDD engineers, the students tackled the problem head-on.
“They initially thought the issue might be in their experimental setup,” said Overby. “But when we modeled their data on our end, it matched perfectly with their findings. They were discovering known phenomena about the way copper reaches saturation under certain conditions.”
Professor Ott highlighted the value of setbacks in the engineering process. “We were surprised by the results but recognized that engineering design often leads to unexpected outcomes compared to initial analyses,” said Ott.
The OMD project stands as a testament to the value of interdisciplinary teamwork, creative problem solving and persistence. Despite complications, the students demonstrated their ability to pivot, learn from setbacks and ultimately deliver a solution that met NSWCDD’s specifications. The final product elevates testing standards and provides a cost-effective platform for rapid and repeatable testing.
Real-world benefits for the Navy
The dynamometer design introduced several advancements that have immediate implications:
Remote control capabilities: Students integrated a non-electrical, pneumatic system, enabling the dynamometer to be operated from up to 30 feet away. This setup makes it safer and easier to use the dynamometer during high-power tests.
Universal adapter: The custom universal adapter design simplifies attachments across various motor types, saving time and resources by eliminating the need for extensive reconfigurations.
Failsafe coupling system: A unique safety feature in the coupling system ensures that inexpensive components absorb failures, protecting more expensive parts in the event of overloads.
The OMD aligns with the broader goals of the Navy: Increasing operational readiness that protects lives while reducing costs.
By improving testing efficiency and reliability, the dynamometer supports development cycles for weapon systems, offering critical insights into their effectiveness against threats.
“Testing boat motors used to require extensive setups with generators, chillers and pumps,” said Overby. “The students’ system removes much of that complexity, providing a streamlined, reliable and reproducible tool that we can integrate immediately.”
From classroom to real life
For students, this project offered far more than technical experience; it provided a window into the complexities of engineering for national security.
“It was fun to finally apply the knowledge and skills we developed over the past three years to something real,” said Barnett.
Through collaboration with NSWCDD engineers, the students learned how real engineering teams operate, from managing projects within tight budgets and timelines to dealing with testing and revision.
When students completed the IDC program, they emerged as engineers with hands-on experience. And each contributor to the dynamometer project, including Barnett, Jaeden Schreier and Benjamin Thompson, played a role in developing a device that is currently being used at NSWCDD to enhance effects analysis.
Bridging academia and industry with vision
The success of the dynamometer project illustrates the value of government-academia partnerships. Virginia Tech’s cross-disciplinary approach to capstone projects ensures that graduates are well-prepared to meet industry demands.
At NSWCDD, the benefits extend far beyond completing a single project. These collaborations fuel the Navy’s mission while cultivating a pipeline of new engineers equipped with the necessary skills and mindset to contribute to defense modernization.
The dynamometer is just the beginning. Conversations are already underway for new projects that will test interdisciplinary teams, further driving opportunities for students and the Navy alike.
“Whether or not the students decide to work for the Navy, they leave with an understanding of the mission and its importance,” said Overby. “Having fresh talent who already know our organization and are equipped to seamlessly integrate into our teams shortens the learning curve for graduating engineers.”