Carlos Castro

Biomechatronic Foot + Leg

Emulate the dexterity and range of motion of a human foot + adding a knee and hip joint to allow for proper gait motion. Applications to legged locomotion and robotics.

The aim of this project is to create a dexterous mechatronic foot modeled after the physiology of human and primate feet. Applications of this project are directed towards legged locomotion systems found in robotics and powered prosthesis.

Conventional humanoid robotics utilize the “flat foot” model, where there are no supporting arches and minimal range of motion within the foot. But as seen in everyday animal biology, the foot collectively uses both passive and active (powered) structures to create a remarkably mobile and stable system. The Biomechatronic Foot aims to replicate the dynamics and range of motion of a human foot by means of having both passive (supporting) and active (powered) compliant structures. The complexity of biology will be reduced to the primary and dominating mechanical degrees of freedom while allowing the necessary motion of the forefoot, heel, and ankle. The foot is the focus, but adding a knee and hip joint will allow for proper gait motion/studies.

Past Biomechatronic Foot designs have implemented very nimble powered toes as well as an array of mechanical structures to mimic the functionality of a human foot. Different sensor types have been used to test and monitor the stability and dynamics of the foot. Continued development of the Biomechatronic Foot will involve investigating mechanical means of achieving complex flexion and extension of the toes as well as flexion, extension, and roll of the ankle, investigating compliance mechanisms, investigating more robust actuation, increasing the quality and number of sensors placed throughout the foot, incorporating effective control systems, among other improvements.

Videos:

2025-2026

Control of Free-Falling Bodies

Actively and/or passively control the dynamics of a free-falling body. Applications to atmospheric-entry systems, satellite attitude control, stuntronic robots.

Project sponsored by Lockheed Martin Corporation

The aim of this project is to investigate and develop a system to actively and/or passively control the orientation (stability) of a free-falling body. The primary aims of the project are to investigate the dynamics associated with such motion and the mechanical means to control the motion. Active control will be done by either (or a combination of) active control surfaces, gyroscopic stability such as reaction wheels or control moment gyroscopes, or simply by controlling the extension and retraction of body segments. Passive control will be done by either (or a combination of) inherent stability of the body, or quasi-static control surfaces. Future applications of this project are directed towards space applications such as atmospheric-entry vehicle/capsule design studies, atmospheric collection systems to study planetary atmospheres, satellite attitude control, and stuntronics for aerial robotic entertainment.

Previous projects have involved the design and simulation of a free-falling multi-legged aerial robot and the prototyping of a 3D reaction wheel system for satellite attitude (orientation) control. The direction of this project will be based on common interests. *** Strong knowledge in Dynamics recommended***

Vertical Wind Tunnel 

Small (tabletop size) vertical wind tunnel to test small and scaled bodies. Applications to investigating the flow dynamics of bodies under free-fall.

Project sponsored by Lockheed Martin Corporation

The aim of this project is to design and build a small (tabletop size) vertical wind tunnel system. The end result is to have a system for flow visualization and flow characterization over a body. Characterization implies the ability to extract data in a controlled manner, therefore an array of sensors will be used. Future usage of the vertical wind tunnel will be to investigate scaled models associated with the Control of Free-Falling Bodies project and serve as a general educational tool. Continued development of the vertical wind tunnel will involved improving the flow within the structure through CFD studies, changing the wind tunnel type, incorporating appropriate sensors (pressure taps, load cells, ect), investigating flow visualization methods.

Past vertical wind tunnel build available to improve upon.

Videos:

2025-2026

Automotive Wind Tunnel 

Small wind tunnel to test small and scaled vehicles. Applications to investigating automotive flow dynamics of racing and road vehicles.

The aim of this project is to design and build a wind tunnel for scaled vehicles 1:24/1:18 (e.g. Tamiya scaled cars, I have some of these). This wind tunnel will include a moving ground system to more appropriately capture wheel rotation and boundary layers effects. The end result is to visualize and characterize the flow over a vehicle.

Past vertical wind tunnel build available to improve upon.

Videos:

2025-2026

Flow Visualization of Fluid and Heat Dynamics

Create an array of fluid and heat visualization demos.

The aim of this project is to develop an array of fluid and heat visualization demos. Fluid and thermal sciences are deeply rooted in a mathematical framework, making it difficult to connect theory to reality. Having the ability to “see” theory, hence move from a mathematical framework to a physical one, undeniably creates a deeper understanding and appreciation of the underlying principles. Flow visualization allows students to see and analyze principles in action, linking abstract equations of the classroom to real-world behavior.

Potential topics for demos include: fluid properties (linear/nonlinear), vorticity, vortex shedding, conduction, convection, thermal gradients, multiphase flows, turbulence, radiation, phase transitions, chaos, as well as industry-relevant applications (such as aero/hydro-dynamics, automotive, biomedical, electronic cooling, energy generation, environmental, space exploration).

Tools to be used are: computational (simulation software), experimental: dye/gas injection, particle image velocimetry (PIV), Schlieren imaging, and thermal imaging. 

The beauty of fluid flow and heat will be seen, appreciated, studied, and understood.