From the ground into the air: Trine students working with advanced resins

By Avalon Schnelker
English ‘27

Trine University has received a grant from the Indiana Space Grant Consortium (INSGC) to support students conducting advanced aerospace composite research.

Mechanical engineering students are leading a hands-on project titled “Resin Infusion for Aerospace Composites,” guided by Gurudutt Chandrashekar, Ph.D., associate professor in the Wade Department of Mechanical and Aerospace Engineering. The project explores vacuum-assisted resin infusion—an industry-standard fabrication method known for producing lighter, stronger composite structures by improving the fiber-to-resin ratio and reducing material waste.

Rising interest in composites

Joshua Danielowski, a mechanical engineering major from Archbald, Pennsylvania, learned about the project through an email from Dr. Chandrashekar, who also advises Trine’s AIAA Design, Build, Fly (DBF) Senior Design Team.

Eryn Pikus, a mechanical engineering major from Carmel, Indiana, was already familiar with the DBF team and knew early in the year that they were seeking student interns. After helping another senior design group the previous year, she was eager to take on a more involved role.

Eryn joined the Space Grant project without knowing exactly what to expect. As she explored the process of making resin-infused components, she became increasingly fascinated.

“It is a type of work that is almost completely based on your prep work,” she said. As long as everything is prepared “before you mix the resin with the hardener, then everything should go how you want it to if you follow the process.”

Joshua was drawn to the project because it provided specialized, hands-on composite experience that aligned with his passion for aerospace engineering. After completing a manufacturing internship at MacLean-Fogg Component Solutions, he was looking for a role that matched his practical background. This project, he said, became “the perfect way to gain relevant engineering experience,” especially given his demanding schedule as a student-athlete.

He added that the experience will be “invaluable, not only for my upcoming senior design project but also for building a strong foundation for my post-graduation career.”

Design, Build, Fly applications

Students in the project are exploring resin infusion techniques to fabricate components such as wings and fuselage sections for the AIAA Design/Build/Fly (DBF) competition. This annual national challenge tasks student teams with designing, fabricating, and flying a radio-controlled aircraft—providing authentic experience in design, testing, and manufacturing.

One of the project’s major outcomes is the development of a Resin Infusion Checklist Booklet, a comprehensive guide covering materials, preparation steps, and procedures. Future Trine teams will be able to rely on this resource for composite-related projects.

Fabricating flight-ready parts

Eryn and Joshua are also responsible for maintaining the composites lab and training other senior design students in safe and effective composites fabrication practices so they can manufacture flight-ready DBF components.

“Our current focus is on overcoming the technical challenges to create a reliable and repeatable infusion setup,” Joshua explained.

Eryn noted that she realized there is no single “scientific method” for mold or component preparation, and even small details can significantly affect the final part. She also learned how limited the working time once resin and hardener are mixed.

Her biggest takeaway: Thorough preparation is essential.

Scaling from small test samples to full, flight-worthy aircraft components has been a learning curve for both students, revealing many additional variables that must be controlled.

Joshua emphasized that the project is not only about producing composite parts, but also about improving the process—“identifying those variables, refining our techniques, and ensuring our manufacturing process is consistent and repeatable.”

Turning ‘failures’ into learning moments

As the project moves forward, Joshua says he will continue to draw on the “learning experiences”—moments when things didn’t go as planned and required thoughtful analysis and engineering solutions. Challenges in areas such as mold setup and sealing techniques helped the team continually refine their process.

Eryn said the project significantly strengthened her skills in material preparation and taught her the importance of planning ahead. She also learned to maintain a calm and steady hand during resin application, since carbon fiber can easily shift.

Joshua added that the project has allowed him to help build “a lasting resource for the university,” contributing to a well-documented composite lab that future teams can use and improve.

“It’s been rewarding to see the facility improve, knowing we’re laying the groundwork for future innovation here at Trine,” he said.