{"id":216022,"date":"2026-05-04T11:49:25","date_gmt":"2026-05-04T15:49:25","guid":{"rendered":"https:\/\/www.hajim.rochester.edu\/senior-design-day\/?p=216022"},"modified":"2026-05-04T11:49:25","modified_gmt":"2026-05-04T15:49:25","slug":"baseball-bat-contour-analysis","status":"publish","type":"post","link":"https:\/\/www.hajim.rochester.edu\/senior-design-day\/baseball-bat-contour-analysis\/","title":{"rendered":"Baseball Bat Contour Analysis"},"content":{"rendered":"\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"576\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-9-2-1024x576.jpeg\" alt=\"\" class=\"wp-image-229462\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-9-2-1024x576.jpeg 1024w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-9-2-300x169.jpeg 300w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-9-2-768x432.jpeg 768w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-9-2-1536x864.jpeg 1536w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-9-2-2048x1152.jpeg 2048w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-9-2-1920x1080.jpeg 1920w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-9-2-340x191.jpeg 340w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-9-2-660x371.jpeg 660w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<p style=\"font-size:30px\"><strong>Team Members<\/strong><\/p>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:100%\">\n<div class=\"wp-block-coblocks-row coblocks-row-328152947859\" data-columns=\"4\" data-layout=\"25-25-25-25\"><div class=\"wp-block-coblocks-row__inner has-no-padding has-no-margin is-stacked-on-mobile has-medium-gutter\">\n<div class=\"wp-block-coblocks-column coblocks-column-32815295025\" style=\"width:24.34%\"><div class=\"wp-block-coblocks-column__inner has-no-padding has-no-margin\"><div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"400\" height=\"400\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/mel-pic-7.jpeg\" alt=\"\" class=\"wp-image-225242\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/mel-pic-7.jpeg 400w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/mel-pic-7-300x300.jpeg 300w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/mel-pic-7-150x150.jpeg 150w\" sizes=\"auto, (max-width: 400px) 100vw, 400px\" \/><figcaption class=\"wp-element-caption\">Melanie Landis<\/figcaption><\/figure>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-coblocks-column coblocks-column-32815295026\" style=\"width:25.66%\"><div class=\"wp-block-coblocks-column__inner has-no-padding has-no-margin\"><div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full is-resized\"><img loading=\"lazy\" decoding=\"async\" width=\"400\" height=\"400\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/nat-pic-5.jpeg\" alt=\"\" class=\"wp-image-225252\" style=\"width:189px;height:auto\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/nat-pic-5.jpeg 400w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/nat-pic-5-300x300.jpeg 300w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/nat-pic-5-150x150.jpeg 150w\" sizes=\"auto, (max-width: 400px) 100vw, 400px\" \/><figcaption class=\"wp-element-caption\">Natalie Shank<\/figcaption><\/figure>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-coblocks-column coblocks-column-32815295027\" style=\"width:25%\"><div class=\"wp-block-coblocks-column__inner has-no-padding has-no-margin\"><div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"233\" height=\"232\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-8-3.jpeg\" alt=\"\" class=\"wp-image-225262\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-8-3.jpeg 233w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-8-3-150x150.jpeg 150w\" sizes=\"auto, (max-width: 233px) 100vw, 233px\" \/><figcaption class=\"wp-element-caption\">Jack Todd<\/figcaption><\/figure>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-coblocks-column coblocks-column-32815295027\" style=\"width:25%\"><div class=\"wp-block-coblocks-column__inner has-no-padding has-no-margin\"><div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"389\" height=\"389\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/sam-pic-3.jpeg\" alt=\"\" class=\"wp-image-225272\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/sam-pic-3.jpeg 389w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/sam-pic-3-300x300.jpeg 300w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/sam-pic-3-150x150.jpeg 150w\" sizes=\"auto, (max-width: 389px) 100vw, 389px\" \/><figcaption class=\"wp-element-caption\">Samuel Zeltman<\/figcaption><\/figure>\n<\/div><\/div><\/div>\n<\/div><\/div>\n<\/div>\n<\/div>\n\n\n\n<p style=\"font-size:30px\"><strong>Sponsor<\/strong><\/p>\n\n\n\n<p>JJ Ruby &#8211; <strong><em>Senior Director, Research and Development, Houston Astros<\/em><\/strong><\/p>\n\n\n\n<p>Adam Brodie &#8211; <strong><em>Assistant Director of Research, Houston Astros<\/em><\/strong><\/p>\n\n\n\n<p style=\"font-size:30px\"><strong>Abstract<\/strong><\/p>\n\n\n\n<p><em>This project was about designing a portable device that can measure the contour of a baseball bat precisely to understand the connection between on-field performance and different curvature profiles. Right now, baseball organizations have limited information on the specific contour details of bats. We built a portable, non-damaging system that measures the contour of all acceptable MLB bat sizes.<\/em><\/p>\n\n\n\n<p><em>Initial testing has been completed, and the results indicate that the data does not yet fall within the specified parameters outlined in the project requirements. The team is currently working to improve both data processing methods and the mechanical performance of the system. Vibrations generated by the servo motor while rotating the lead screw are negatively affecting the accuracy of data collection, so solutions to reduce vibration are actively being developed and tested.<\/em><\/p>\n\n\n\n<p style=\"font-size:30px\"><strong>Problem Statement<\/strong><\/p>\n\n\n\n<p>Recent innovations in baseball bat design have introduced increasingly complex and performance-driven curvature profiles, redefining how athletes optimize swing dynamics and contact precision. To fully unlock the performance potential of these designs, rapid and highly accurate curvature modeling is essential for advanced analysis, iteration, and data-driven decision making. However, many existing measurement solutions are costly, time-intensive, or lack portability, limiting their practical use in dynamic team environments. This lack of data causes teams to be at a disadvantage compared to their opponents when it comes to deciding the best curvature for their players. <strong>The Houston Astros seek to pioneer a fast, portable, and precise method for capturing and recording the 2D contour of a baseball bat\u2019s length and cup, enabling real-time insights and streamlined evaluation.<\/strong><\/p>\n\n\n\n<p style=\"font-size:30px\"><strong>Requirements<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The device must measure the contour of a baseball bat as a function of length<\/li>\n\n\n\n<li>The device must measure the contour of the cup of a baseball bat, if it is present<\/li>\n\n\n\n<li>The device must be able to be moved by one person<\/li>\n\n\n\n<li>The device must be able to be transported between cities<\/li>\n\n\n\n<li>The device must take quick measurements<\/li>\n<\/ul>\n\n\n\n<p style=\"font-size:30px\"><strong>Specifications<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Measurements of the baseball bat must be completed in under 10 minutes<\/li>\n\n\n\n<li>Measurements of the contour must be accurate within 0.005 inches<\/li>\n\n\n\n<li>The length of the device must not exceed 4.5 feet<\/li>\n\n\n\n<li>The width of the device must not exceed 2.5 feet<\/li>\n\n\n\n<li>The device must measure a bat of length between 30\u201d-36\u201d<\/li>\n<\/ul>\n\n\n\n<p style=\"font-size:30px\"><strong>Design<\/strong><\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"437\" height=\"762\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Screenshot-2026-04-23-221646.png\" alt=\"\" class=\"wp-image-224262\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Screenshot-2026-04-23-221646.png 437w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Screenshot-2026-04-23-221646-172x300.png 172w\" sizes=\"auto, (max-width: 437px) 100vw, 437px\" \/><figcaption class=\"wp-element-caption\"><em>Final CAD Assembly<\/em><\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"600\" height=\"800\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-6.jpeg\" alt=\"\" class=\"wp-image-224372\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-6.jpeg 600w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Image-6-225x300.jpeg 225w\" sizes=\"auto, (max-width: 600px) 100vw, 600px\" \/><figcaption class=\"wp-element-caption\"><em>Final Assembly<\/em><\/figcaption><\/figure>\n\n\n\n<p style=\"font-size:30px\"><strong>Mechanical Analysis<\/strong><\/p>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Tolerance Analysis<\/summary>\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p>A primary tolerance issue encountered early in the design process was the straightness tolerance on the stanchions\/alignment rods that held the knob end conical fixture. Significant straightness deviations of these stanchions could result in tilting of the bat, as illustrated in the figure below. <\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"591\" height=\"608\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-38.png\" alt=\"\" class=\"wp-image-225292\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-38.png 591w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-38-292x300.png 292w\" sizes=\"auto, (max-width: 591px) 100vw, 591px\" \/><figcaption class=\"wp-element-caption\"><em>Diagram of straightness tolerance propagation as you move down aluminum extrusion long enough for baseball bat centering fixture.<\/em><\/figcaption><\/figure>\n\n\n\n<p>Our group originally was intending on using aluminum extrusions with a linear guide that would have a conical fixture attached to it. This guide would then slide down and rest on the knob of the baseball bat, using its own weight to center it with the bottom conical fixture on the barrel end of the bat. Testing was done on a piece of aluminum extrusion that was potentially going to be used as the rail system for the knob end conical fixture using a FARO Arm scanner. Results of this testing can be seen in the figure below.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"538\" height=\"403\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-39.png\" alt=\"\" class=\"wp-image-225302\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-39.png 538w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-39-300x225.png 300w\" sizes=\"auto, (max-width: 538px) 100vw, 538px\" \/><figcaption class=\"wp-element-caption\"><em>FARO Arm straightness test data of aluminum extrusion<\/em><\/figcaption><\/figure>\n\n\n\n<p>From this data, statistical analysis was done on the slope of the best fit lines for each trial set of data. Specifically, a t-distribution was used (less than 30 trials were conducted) with the following equation:<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"170\" height=\"39\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-40.png\" alt=\"\" class=\"wp-image-225312\"\/><\/figure>\n\n\n\n<p>In this specific case our t-value would be 2.262, based on us having 10 trials and wanting a 95% confidence level, the standard deviation (S) for the slope values would be 3.4328e-05\u201d, and n would be the same as the number of trials, 10. From the trials and the statistical analysis, the extrusion would have a straightness deviation of 0.00109\u201d \u00b1 2.46e-05\u201d per inch of extrusion length with 95% confidence. This would lead to approximately 0.040\u201d straightness tolerance once you reach the end of the 37 inches needed for the design. The team decided this value was significantly too large for our applications, so we looked for alternatives.<\/p>\n\n\n\n<p>Thomson rods, specifically 0.75\u201d diameter self-supporting rods with part number 8350T93 from McMaster Carr, were chosen for our design. These rods have a 0.002\u201d per 1 foot of length straightness tolerance, which is much tighter controlled when compared to the aluminum extrusion previously being discussed. This would lead to a total straightness tolerance of 0.006\u201d at the end of the rods, a large reduction from the 0.040\u201d using the aluminum extrusion. However, the longest self-supporting Thomson rods the team could find were 25 inches long. Intermediate stanchion members that were created on the lathe, using 6061 Aluminum round stock. From the vendor, these bars have straightness tolerance of 0.0125\u201d per 1 foot of length, comparable to that of the aluminum extrusions previously mentioned. When combining these two components, the total straightness tolerance would be approximately 0.0167\u201d by the time you reach the end of the rods. This is still a greater than 50% reduction in straightness tolerance across the rail system.<\/p>\n<\/details>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Fastener Torque Calculation<\/summary>\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p>The fasteners that were determined to be the most critical were the M6 fasteners that connected the base plates to the aluminum extrusion frame\/base. These fasteners would have to support the largest load in the identified worst-case scenario set up. In this case the worst-case scenario would be if the entire fixture assembly were to be turned upside down, so the entire weight of the fixture would be loaded onto the 12 fasteners that held the two base plates down. The total weight of the fixture components was determined to be 30.0441 lbf, as shown in the figure below, when divided among the 12 fasteners that would be 2.504 lbf\/fastener acting in tension.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1001\" height=\"556\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-42.png\" alt=\"\" class=\"wp-image-225332\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-42.png 1001w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-42-300x167.png 300w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-42-768x427.png 768w\" sizes=\"auto, (max-width: 1001px) 100vw, 1001px\" \/><figcaption class=\"wp-element-caption\"><em>Fastener torque calculation<\/em><\/figcaption><\/figure>\n\n\n\n<p>To begin, the analysis\/calculation a preload of 75% of the proof load of the fastener was used, considering the group wanted nonpermanent connections on these fasteners so it could be disassembled as necessary. Due to the low loads expected on these fasteners, there was an expectation that the bolt preload would not be anywhere close to the preload required to reach 75% of the proof load. For this reason, the total load per fastener was considered in the comparison to ensure that we had enough fasteners and plate separation would not occur. This is opposed to determining the portion of the load that goes through the fastener directly and the member directly. For these purposes, the stiffness of the bolt and the stiffness of the members in the bolted connection were not required, due to the group using a more conservative approach by using the total tensile load at each bolted joint. This would result in a conservative comparison number, since the load we would be comparing too would be greater than the actual load in the fastener. The preload required to reach 75% of the proof strength for the M6 fasteners was 3292.08 lbf per bolt, which is much higher than the total tensile load per bolted connection, which was 2.504 lbf. This means that we are nowhere near plate separation occurring. For the torque calculation itself, the equation below was used:<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"162\" height=\"46\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-41.png\" alt=\"\" class=\"wp-image-225322\"\/><\/figure>\n\n\n\n<p>Where T is the fastener torque, K is the nut factor, D is the nominal fastener diameter, and Fi is the preload. In this case a nut factor of 0.30 was used, which is common for black finished fasteners. This results in a fastener torque requirement of 229.3 lbf-in.<\/p>\n<\/details>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Material Selection<\/summary>\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p>To further guide the design direction of our fixturing mechanism, a structural analysis was performed to compare the displacement of the conical fixture (Concept 1) between two materials. Initially, the fixture was designed to be printed out of ABS plastic. After discussion of the precision of the 3D printing process as well as the team\u2019s desire to use the fixture interfaces to position other components, aluminum was also considered. A finite element model was created to analyze the displacement of the conical fixture. The load used in the analysis was approximately the weight of one baseball bat at about 30 oz or 1.875 lbf, applied in a ring at the maximum diameter of the barrel (2.61 in), see Figure B1 for the fixture concept set up. The fixture was fully constrained in the x, y, and z at the bolt holes, and it was also constrained in the z along the bottom surface representing the raised platform of the fixture.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"921\" height=\"518\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-43.png\" alt=\"\" class=\"wp-image-225342\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-43.png 921w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-43-300x169.png 300w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-43-768x432.png 768w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-43-340x191.png 340w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-43-660x371.png 660w\" sizes=\"auto, (max-width: 921px) 100vw, 921px\" \/><figcaption class=\"wp-element-caption\"><em>Analysis of the base conical bat fixture discussed in concept 1. Results show that Aluminum 6061 has approximately 100 times less displacement than ABS<\/em><\/figcaption><\/figure>\n\n\n\n<p>This figure shows the FEM and simulation set up as well as results comparing the ABS plastic and Aluminum fixtures. In comparing the displacement, the fixture made of aluminum 6061 had approximately 100x less displacement (magnitude) than the ABS fixture. This supports the team&#8217;s decision to create both conical fixtures for the bat out of aluminum for structural reasons. The material choice and manufacturing process also provides more control over the tolerances of fixture features that mate with other components in the apparatus. The solution used for this analysis was 101 Linear Statics. The model functions under the assumption that material behavior can be characterized as linear, meaning that as the load increases, the displacement can be scaled linearly. For the ABS, if the fixture were to be loaded with 10 times the weight of the bat, which may happen in the case of misalignment or improper use, the fixture could see a displacement on the order of magnitude of allowable tolerance on the bat contour measurement. With the aluminum, a 10x load of the bat weight will not have the same effect and therefore it is the material choice that the team will move forward with.<\/p>\n<\/details>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Computer-Base Analysis<\/summary>\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p>The analysis chosen for this section was a structural finite element model of the Thomson rod mounting beam. The structure had the weight of two Thomson rods applied at their respective mounting locations on the beam. The weight of the rods was applied over the area of the nut and the bolt holes were represented using an RBE2 as well as fixed in all translational directions to represent fastening and clamping force. See Figure D6 in the annex for the FEM set up and results. The maximum displacement in the x direction is approximately one order of magnitude less than our accuracy specification. From this result, the model shows that the displacement in the x direction, corresponding to the distance between the sensor and the bat, makes a negligible contribution to the error in the system.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"578\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-44-1024x578.png\" alt=\"\" class=\"wp-image-225352\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-44-1024x578.png 1024w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-44-300x169.png 300w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-44-768x434.png 768w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-44-340x191.png 340w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/image-44.png 1031w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\"><em>Computer Based Analysis<\/em><\/figcaption><\/figure>\n<\/details>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<p style=\"font-size:30px\"><strong>Testing<\/strong><\/p>\n\n\n\n<p>To verify system measurement time, the longest of the four tested bats was placed in the fixture. Measuring the full length from the barrel base to the knob took approximately 7 minutes and 15 seconds. A maximum barrel diameter of 2.61 inches requires an additional 55 seconds for horizontal measurement, resulting in a total lead screw movement time of about 8 minutes and 10 seconds, which meets the measurement time specification.<\/p>\n\n\n\n<p>To evaluate contour accuracy, a ground cylinder (0.25-inch diameter) was measured. Due to vibrations from lead screw oscillations, a clear contour could not be obtained. The data was smoothed using MATLAB\u2019s <em>movmean<\/em> function to approximate a bat-like contour; however, this reduced measurement resolution as it included the points from noise and vibration.<\/p>\n\n\n\n<p>The dimensions of the device correspond to the portability requirement for the project. After assembly, the device was verified to be in the design envelope (also used in the CAD) defined by the design requirements. The design of the fixture has an adjustable conical fixture, which allows for lifting and lowering of the fixture, accommodating the 30\u201d-36\u201d specification, answering the requirement for accommodating bats of different lengths.<\/p>\n\n\n\n<p>Seen below are the current scans of the example baseball bats.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"755\" height=\"564\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Picture3-2.png\" alt=\"\" class=\"wp-image-230312\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Picture3-2.png 755w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Picture3-2-300x224.png 300w\" sizes=\"auto, (max-width: 755px) 100vw, 755px\" \/><figcaption class=\"wp-element-caption\"><em>Example cup scans of all baseball bats<\/em><\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"842\" height=\"339\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Picture2-3.png\" alt=\"\" class=\"wp-image-229392\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Picture2-3.png 842w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Picture2-3-300x121.png 300w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/Picture2-3-768x309.png 768w\" sizes=\"auto, (max-width: 842px) 100vw, 842px\" \/><figcaption class=\"wp-element-caption\"><em>Smoothed moving average of full bat contour<\/em><\/figcaption><\/figure>\n\n\n\n<p style=\"font-size:30px\"><strong>Recommendations for Future Work<\/strong><\/p>\n\n\n\n<p>Future work for this project should focus on improving the accuracy and reliability of the measurement system. The most critical area for improvement is reducing the measurement noise caused by vibration in the lead screw mechanism and limitations of the current sensing approach. This could be addressed through both mechanical and control improvements, such as implementing a more stable motion system (e.g, belt-driven stage or precision ball screw). Linear encoders can be implemented as part of the servo motors to provide precise position feedback. Updating the sensor system could also assist in providing the necessary measurement resolution that aligns with the \u00b10.005-inch accuracy specification.<\/p>\n\n\n\n<p>To support these improvements, a comprehensive validation and calibration protocol should be developed, including repeatability testing and a full system uncertainty quantification.<\/p>\n\n\n\n<p>Finally, adjusting the data collection process would help to increase the practical value of the device. If automated data processing and improved filtering techniques could be integrated into the system, this would not require data manipulation by the discretion of the user.<\/p>\n\n\n\n<p style=\"font-size:30px\"><strong>Acknowledgements<\/strong><\/p>\n\n\n\n<p>We would like to thank Professor Muir, Adam Brodie, and JJ Ruby for their time, knowledge, and efforts dedicated to the success of this project. We would also like to thank Samantha Kriegsman, Jim Alkins, Bill Mildenberger, Chris Pratt, and Kyle Christensen for their invaluable assistance throughout this project.<\/p>\n\n\n\n<p style=\"font-size:30px\"><strong>Final Design Review<\/strong><\/p>\n\n\n\n<div data-wp-interactive=\"core\/file\" class=\"wp-block-file\"><object data-wp-bind--hidden=\"!state.hasPdfPreview\" hidden class=\"wp-block-file__embed\" data=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/GateD_FDRBaseballME205.pdf\" type=\"application\/pdf\" style=\"width:100%;height:600px\" aria-label=\"Embed of GateD_FDRBaseballME205.\"><\/object><a id=\"wp-block-file--media-a0fb241c-9d8d-46d4-8a3e-473e27368ae9\" href=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/GateD_FDRBaseballME205.pdf\">GateD_FDRBaseballME205<\/a><a href=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/GateD_FDRBaseballME205.pdf\" class=\"wp-block-file__button wp-element-button\" download aria-describedby=\"wp-block-file--media-a0fb241c-9d8d-46d4-8a3e-473e27368ae9\">Download<\/a><\/div>\n\n\n\n<p style=\"font-size:30px\"><strong>Team Presentation Video<\/strong><\/p>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<div class=\"wp-embed\"><div class=\"wp-embed-wrap\"><iframe loading=\"lazy\" title=\"Senior Design Team Baseball Final Video\" width=\"1062\" height=\"597\" src=\"https:\/\/www.youtube.com\/embed\/KynFD1j1B58?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe><\/div><\/div>\n<\/div><\/figure>\n\n\n\n<p style=\"font-size:30px\"><strong>Additional Photos<\/strong><\/p>\n\n\n\n<figure class=\"wp-block-gallery has-nested-images columns-default is-cropped wp-block-gallery-1 is-layout-flex wp-block-gallery-is-layout-flex\">\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"229972\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/1dd179bf-2751-4966-8e08-f1a653bcb1d9-1.jpg\" alt=\"\" class=\"wp-image-229972\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/1dd179bf-2751-4966-8e08-f1a653bcb1d9-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/1dd179bf-2751-4966-8e08-f1a653bcb1d9-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"450\" data-id=\"229982\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/2f2b45b9-a0f7-46a3-86e5-e0e6384213cd-1.jpg\" alt=\"\" class=\"wp-image-229982\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/2f2b45b9-a0f7-46a3-86e5-e0e6384213cd-1.jpg 800w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/2f2b45b9-a0f7-46a3-86e5-e0e6384213cd-1-300x169.jpg 300w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/2f2b45b9-a0f7-46a3-86e5-e0e6384213cd-1-768x432.jpg 768w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/2f2b45b9-a0f7-46a3-86e5-e0e6384213cd-1-340x191.jpg 340w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/2f2b45b9-a0f7-46a3-86e5-e0e6384213cd-1-660x371.jpg 660w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large is-style-default\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"229992\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/4c347d39-807a-4a1b-ba9c-f64c43ad6ac6-1.jpg\" alt=\"\" class=\"wp-image-229992\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/4c347d39-807a-4a1b-ba9c-f64c43ad6ac6-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/4c347d39-807a-4a1b-ba9c-f64c43ad6ac6-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230022\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/4de2acd6-5c39-49cf-9aaf-aa54f5c93c97-1.jpg\" alt=\"\" class=\"wp-image-230022\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/4de2acd6-5c39-49cf-9aaf-aa54f5c93c97-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/4de2acd6-5c39-49cf-9aaf-aa54f5c93c97-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230002\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/4feae3ae-5b37-4f97-b8c7-b2e222060db9-1.jpg\" alt=\"\" class=\"wp-image-230002\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/4feae3ae-5b37-4f97-b8c7-b2e222060db9-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/4feae3ae-5b37-4f97-b8c7-b2e222060db9-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230032\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/5ebe21be-1633-4771-914d-eb83c9295f3f-1.jpg\" alt=\"\" class=\"wp-image-230032\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/5ebe21be-1633-4771-914d-eb83c9295f3f-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/5ebe21be-1633-4771-914d-eb83c9295f3f-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230042\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/9d28b544-52af-4a7e-b796-a2d3df96b8a2-1.jpg\" alt=\"\" class=\"wp-image-230042\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/9d28b544-52af-4a7e-b796-a2d3df96b8a2-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/9d28b544-52af-4a7e-b796-a2d3df96b8a2-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230052\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/018ff396-8691-4280-b3c8-d7dddf01da48-1.jpg\" alt=\"\" class=\"wp-image-230052\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/018ff396-8691-4280-b3c8-d7dddf01da48-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/018ff396-8691-4280-b3c8-d7dddf01da48-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230082\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/64b6f069-4333-4887-b10d-c028e8a1a909-1.jpg\" alt=\"\" class=\"wp-image-230082\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/64b6f069-4333-4887-b10d-c028e8a1a909-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/64b6f069-4333-4887-b10d-c028e8a1a909-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230132\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/493b2c9d-2409-48a9-a925-46b7c96e3ab7-1.jpg\" alt=\"\" class=\"wp-image-230132\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/493b2c9d-2409-48a9-a925-46b7c96e3ab7-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/493b2c9d-2409-48a9-a925-46b7c96e3ab7-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230122\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/995ddb90-2986-4969-a419-be16767cd5cd-1.jpg\" alt=\"\" class=\"wp-image-230122\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/995ddb90-2986-4969-a419-be16767cd5cd-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/995ddb90-2986-4969-a419-be16767cd5cd-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230092\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/21396e40-a341-4d70-981d-cd8c864be87c-1.jpg\" alt=\"\" class=\"wp-image-230092\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/21396e40-a341-4d70-981d-cd8c864be87c-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/21396e40-a341-4d70-981d-cd8c864be87c-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230112\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/7238598b-4a4b-456c-b98c-23dba60abb6e-1.jpg\" alt=\"\" class=\"wp-image-230112\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/7238598b-4a4b-456c-b98c-23dba60abb6e-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/7238598b-4a4b-456c-b98c-23dba60abb6e-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230102\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/28057319-c70b-44b7-8ce5-8219853f54b5-1.jpg\" alt=\"\" class=\"wp-image-230102\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/28057319-c70b-44b7-8ce5-8219853f54b5-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/28057319-c70b-44b7-8ce5-8219853f54b5-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230142\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/a4da1194-3233-4884-a7bf-b6f64c5e953a-1.jpg\" alt=\"\" class=\"wp-image-230142\" srcset=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/a4da1194-3233-4884-a7bf-b6f64c5e953a-1.jpg 450w, https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/a4da1194-3233-4884-a7bf-b6f64c5e953a-1-169x300.jpg 169w\" sizes=\"auto, (max-width: 450px) 100vw, 450px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"450\" height=\"800\" data-id=\"230192\" src=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2026\/04\/ab1331c5-b826-4a5b-a1d9-f5593467fc79-1.jpg\" alt=\"\" class=\"wp-image-230192\" 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