Senior Design in Materials Science and Engineering
Turning Ideas into Materials that Matter
In the Department of Materials Science and Engineering at the University of Delaware, Senior Design is the culmination of the undergraduate experience – a bridge between classroom learning and professional engineering practice. Each year, our seniors take everything they’ve learned about materials and apply it to an open-ended challenge where creativity meets engineering rigor. Students design, fabricate and test real materials systems – from smart polymers to 3D-printable catalysts transforming scientific theory into practical, impactful technologies.
What is MSEG Senior Design?
Senior Design is the culminating experience of the MSEG undergraduate program, a semester-long, team-based project course, where students work closely with industry or academic sponsors to solve a problem that depends on materials innovation.
Guided by faculty mentors, each team moves through every stage of the engineering process:
- Defining the problem and evaluating constraints and appropriate metrics
- Designing a materials-based solution
- Fabricating and testing prototypes
- Analyzing data and presenting results to sponsors
This immersive experience develops far more than engineering expertise, it cultivates leadership, confidence, managerial skills and the ability to think critically across disciplines.
Students have access to advanced equipment and facilities including:
- Chemical labs for synthesis
- Mechanical Testing Labs
- Advanced Materials Characterization Lab (AMCL)
- UD Nanofabrication Facility
- UD MakerSpace for 3D printing
Recent Projects and Achievements
Each year, MSEG students develop creative and impactful solutions that span a wide range of industries, from sustainable polymers to energy systems and smart infrastructure. Below is a partial list of recent Senior Design projects and their sponsors:
- Polymer Friction Testing Device
Project: Evaluation of Friction Forces of Polymer Surfaces and Medical Device Performance
Sponsor: Terumo Medical Corporation - Reusable Cups Using Sustainable Polymers
Project: Design and Development of a Hot/Cold Cup Using Sustainable Poly(hydroxy butyrate) Copolymers (PHBHX) via 3D Printing or Alternative Processing
Sponsor: Professor John Rabolt - Evaluating Plastic Bag Performance and Degradation
Project: Evaluating Degradation, Circularity, and Performance of Common Plastic Bags
Sponsor: Professor LaShanda Korley, Center for Plastics Innovation (CPI) - Materials for Coating Pharmaceutical Tablets
Project: Designing a Titanium Dioxide-Free Tablet Coating
Sponsor: Merck & Co., Inc. - Polymer Adhesion for Prosthetic Applications
Project: Evaluating Commercially Available Polymers and Elastomers for Adhesion to Aluminum Substrates in Prosthetics
Sponsor: MarinsMed - Electrochemical Sensors for Biopharmaceutical Monitoring
Project: Design, Fabrication, and Characterization of Electrochemical Sensors for Biopharmaceutical Process Monitoring
Sponsor: Professor David Martin - Smart Concrete
Project: Conjugated Polymers in Cement and Concrete
Sponsor: Professor David Martin
- Controlling Biopolymer Liquid Crystal Alignment
Project: Determining Methods for Controlling the Alignment of Biopolymer Liquid Crystals
Sponsor: Professor Darrin Pochan - 3D-Printable Photocatalysts
Project: Design and Fabrication of 3D-Printable Photocatalytic Materials
Sponsor: Professor Christian Pester - Encapsulation for Floating Solar Cells (FPV)
Project: Encapsulation Materials for Solar Cells in Floating Photovoltaic Systems
Sponsor: SHIO Company (Professor Robert Opila) - Freestanding Silicon Nitride Films
Project: Creating Freestanding Si₃N₄ Thin Films via Anisotropic Etching
Sponsor: Professor Xi Wang - Optimizing the Mechanical Strength, Water Resistance and Dimensional Stability of Chemically Modified Wood
Sponsor: Lignolix - Coatings for the Reduction of Tablet and Capsule Degradation
Project: Designing Polymers for reducing the atmospheric degradation of pharmaceuticals.
Sponsor: Merck & Co., Inc. - Al Etching: Seeking F-free Chemical
Project: Optimizing the etch rates of Aluminum surfaces with chemicals that are fluorine-free.
Sponsor: BASF
Why it Matters
Materials engineers shape the future. The properties of materials define what is possible in every field, from medicine, to electronics, to energy and sustainability. Senior Design challenges students to ask:
“What if we could engineer a material that outperforms today’s standards, one that’s stronger, smarter, and more sustainable?”
By the end of the semester, students have created a prototype, tested their design or process, and presented a professional report. These experiences prepare them to drive industry innovation, excel in graduate research and tackle global engineering challenges.
Events and Highlights
Poster Session & Showcase
In December, teams present their design solutions during our Senior Design Poster Session, an open event featuring prototypes, demos and interactive displays. It’s a celebration of innovation, creativity and hard work – a highlight of the MSEG calendar.
Next Showcase: Tuesday, December 9th 2025, Outside of 201 DuPont Hall
Open to: Industry partners, alumni and the UD community.
For Sponsors and Partners
Sponsors play a vital role in Senior Design. Each project is a partnership between students, faculty and organizations who bring real-world problems into the classroom.
As a sponsor, you’ll:
- Gain fresh ideas and insights from top-tier MSEG undergraduates
- Collaborate with faculty who are leaders in materials research
- Access university testing and research facilities
- Build connections with future hires and innovators
To propose a project or learn more about sponsorship, please contact Dr. Ioanna Fampiou at fampiou@udel.edu.
Contact Us
For questions about the MSEG Senior Design Program, sponsorship or events:
Dr. Ioanna Fampiou
Assistant Professor
206 DuPont Hall
University of Delaware
fampiou@udel.edu
Dr. Ismat Shah
Professor
208 DuPont Hall
University of Delaware
ismat@udel.edu