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CU Hyperloop - Tunnel Boring Machine
Project type
Volunteering group project - The Boring Company's Tunnel Boring Competition
Date
March 2024
Location
Texas
Abstract
As part of CU Hyperloop’s 2024 Tunnel Boring Machine team, I performed FEA on the cutting head and front and rear sections structures to ensure safe stress limits under soil resistance and actuator loads. I supported electrical-mechanical integration by coordinating PCB mounts, actuator connections, and internal wire management. I contributed to tunnel path planning, ensuring the machine's hexapod and gripper motions aligned with turning and depth constraints. The TBM integrates a steel cutting head, Stewart platform-based propulsion, vacuum-assisted soil removal, and an onboard tunnel support 3D printer. Our control system used sensor fusion from IMUs, inclinometers, and encoders to enable autonomous motion. I worked closely with propulsion and structure leads to streamline modular design and improve accessibility for testing. We validated the full dig cycle, achieving a 30-inch excavation with synchronized actuation and gripper transitions. My analysis helped identify and reinforce critical stress zones, reducing the risk of plastic deformation. System-level testing confirmed structural integrity, thrust efficiency, and control coordination. This project enhanced my skills in simulation-driven design, cross-functional integration, and real-world validation under field conditions.
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