Blue Origin: Modular Plasma Surface Treatment System with Additively Manufactured Tooling

Discipline: MAE

Advisor: Edward Clutter

Reliable adhesive bonding requires effective surface preparation to increase surface energy and remove contaminants from material surfaces. Inconsistent surface treatment can reduce bond strength, decrease manufacturing reliability, and lead to costly rework. This project addresses these challenges by developing a modular plasma surface treatment system designed to improve the consistency and adaptability of atmospheric plasma applications. The system enhances the functionality of a handheld atmospheric plasma pen through a set of interchangeable, additively manufactured nozzle attachments that control and direct the plasma plume for different treatment geometries and materials. These 3D-printed tooling components allow rapid prototyping and customization while enabling operators to treat a variety of substrates including metals, coated materials, and composite surfaces. Supporting electronic components are integrated to provide controlled operation and create a portable surface treatment platform. By combining modular tooling, additive manufacturing, and integrated electronics, the system improves treatment uniformity and repeatability while adapting to complex surface geometries. This approach supports more reliable adhesive bonding and has potential applications in aerospace, advanced manufacturing, and electronics industries

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