Capstone Reflection

Eight months ago, I embarked on an engineering capstone project. Like many capstones, it started with a convergence of ideas and opportunities. Inspired by innovative recycling projects turning waste High-Density Polyethylene (HDPE) into useful products, and presented with a challenge by a friend needing a way to utilize small, otherwise costly-to-dispose-of Aramid fibers (like Kevlar), a concept was born: Could we combine these two challenging waste streams into something new, something valuable?

Our initial goal was ambitious, bordering on audacious: to create a novel composite material from these recycled components that could potentially offer ballistic resistance. The vision was twofold – contributing to green initiatives by diverting waste from landfills, and exploring the potential to create a material that could enhance safety, perhaps even save lives.

The journey over the subsequent eight months was one of deep immersion, experimentation, and significant learning. While the specific methodology we developed for processing and combining the recycled HDPE and Aramid fibers remains proprietary, the path was far from straightforward. The biggest challenge wasn't necessarily technical, but logistical and personal: finding enough time. Balancing the intense demands of this research and development effort with other commitments required constant juggling and dedication.

On the technical front, the challenges were substantial. Designing a process to effectively integrate these distinct materials required significant research and overcoming hurdles inherent to working with recycled plastics – including managing the Volatile Organic Compounds (VOCs) released during processing, which demanded careful safety considerations. It was a steep learning curve, pushing me to dive deep into the worlds of polymer science, composite materials, and the practical realities of recycling processes.

Despite these hurdles, the results we achieved were nothing short of astonishing and exceeded our initial expectations. We successfully created a new composite material exhibiting:

1. Impressive Strength: Its tensile strength was comparable to other existing composite materials used in demanding applications.

2. Remarkable Lightweight Properties: Perhaps most significantly, our material was approximately 60% lighter than conventional materials offering similar strength.

3. Unexpected Ballistic Resistance: In testing, a sample merely 5mm thick demonstrated the capability to stop an NIJ Level II threat at a close distance of 2 meters – performing effectively even under more stringent conditions than the standard 5-meter test distance.

Witnessing these results was incredibly rewarding. Seeing waste materials transformed into a high-performance composite with such promising characteristics, particularly the combination of strength, low weight, and protective capability, felt like a genuine breakthrough.

Looking back, this capstone project was an invaluable experience. The sheer amount learned about polymers, composites, recycling, and the iterative process of design and testing is immense. Equally important was navigating the non-technical challenges, honing time management and problem-solving skills under pressure.

This new material feels extremely promising. Its unique combination of properties derived from recycled sources opens doors for potential applications where lightweight strength and protection are paramount. While the capstone period has concluded, the journey for this material feels like it's just beginning. I truly wish there were more time and support to continue its development and explore its full potential.

This 8-month deep dive hasn't just resulted in a novel material; it has solidified my passion for material science and sustainable engineering solutions. It’s a powerful reminder that innovation can arise from unexpected places – even from discarded plastics and fiber fragments – and that tackling ambitious goals, even with significant challenges, can lead to truly exciting discoveries.