Ayush Karkare

AAE @ Purdue University

The project began with the goal of addressing the transportation difficulties faced by students on large campuses like Purdue University, where long walks and challenging weather can make commuting inefficient. To solve this, I started converting a standard bike into an electric one, focusing on creating a balance between speed, torque, and practicality. The design utilizes a multi-stage belt drive system, powered by a Flipsky 190kV motor and a Ryobi battery, selected for its ease of swapping during use. Siemens NX was instrumental in the 3D modeling of the custom components, allowing for precise design and efficient integration of off-the-shelf parts from standard part libraries.

The electrical system was a key aspect of the build, requiring careful tuning for optimal performance. I used a PID motion control algorithm to fine-tune the motor, ensuring smooth acceleration and speed regulation. The Flipsky motor was paired with a VESC (Vedders Electronic Speed Controller), which provided real-time feedback and allowed me to dial in precise control over motor behavior. Once the motor was performing as needed, I moved on to the mechanical aspects, where I modeled the bike frame in Siemens NX to ensure accurate fitting of the motor mount and belt drive system. The multi-stage belt system was engineered to deliver both speed and torque while minimizing weight and maintaining stability.

Rapid prototyping played a crucial role in testing and refining the mechanical components. Using a 3D printer, I produced initial prototypes of the motor mount and belt system, which allowed me to quickly identify areas for improvement and make adjustments to the design. This iterative process proved invaluable in fine-tuning the assembly for optimal performance. Currently, I am developing a custom rear wheel assembly that includes a segmented gear system to address the challenges of limited mounting points, with continued prototyping and testing underway.

Looking ahead, I plan to further enhance the system by adding waterproof housings for the electronic components to protect them from environmental elements. Future upgrades include integrating gyroscope sensors, regenerative braking, and variable belt ratios, which will significantly improve performance. These planned developments will move the project beyond its initial phase, adding functionality and robustness to the electric bike conversion.

Biovolt is an innovative energy solution that harnesses photosynthesis to generate electricity while allowing farmers to grow crops. It addresses the land-use dilemma farmers face between growing crops or installing solar farms. By using biophotovoltaic technology, Biovolt captures electrons from plants and soil microbes, converting them into usable electricity. With its modular and customizable design, Biovolt optimizes land use for energy generation without sacrificing agricultural production. For the past four years, I’ve worked with my team to develop Biovolt, and we are now collaborating with Purdue Innovates to bring the product to market.

During the development process, I contributed extensively to the electrical design and construction of Biovolt’s components. My work included configuring the wiring system to optimize both voltage and current by using a combination of series and parallel circuits. The system captures electrons through a coiled copper wire (acting as the cathode) and zinc anodes, which were strategically placed to maximize energy capture from the soil. One of the key challenges was reducing internal resistance within the system, which I addressed by experimenting with different configurations of wiring and materials. In addition, I helped design the panel structure using Fusion 360, and employed a laser cutter to create precise parts, such as the plywood frames for the modular panels. This allowed us to create a robust and scalable system that can be easily installed and maintained.

I also focused on the prototyping and assembly of Biovolt. Using a combination of laser-cut plywood, soil, and landscaping fabric, I assembled the individual cells of each panel, making sure the electrodes were properly mounted and the electrical connections were secure. The system’s modular design allows each panel to function independently, ensuring that if one cell fails, the rest of the system continues to operate. To improve the longevity of the system, the panels were coated with epoxy for waterproofing. The final prototype was tested using a combination of moss and soil, generating approximately 1.56 volts across 19 cells, with the potential for increased output under prolonged sunlight and proper watering.

Looking ahead, the development of Biovolt continues, with plans to enhance the system’s efficiency and scalability. Future iterations will focus on improving the materials for enhanced durability and optimizing the design for large-scale agricultural use. Biovolt has already garnered attention and funding through competitions such as the Purdue University Moonshot Pitch Challenge and JMEC, where we secured $8,500 for further development. With its ability to provide both sustainable energy and agricultural benefits, Biovolt represents a promising solution for the future of farming and renewable energy.

Read more about Biovolt's Participation at the Moonshot Pitch Competition: News Story

As part of Team 81Y VEXMEN Cypher, my team and I engineered a robot for the VEX Robotics Spin Up competition, focusing on shooting discs into goals and controlling field elements. Over the course of the project, we rigorously applied the engineering design process in iterative sprints, documented in detail in our engineering design notebook. This allowed us to manage the project effectively while ensuring that each subsystem was designed, built, and tested to meet specific performance criteria.

One of the core design elements involved leveraging Fusion 360 for CAD modeling. The use of this software allowed us to meticulously design and visualize the robot’s complex components, such as the drivetrain, flywheel, and intake system, ensuring full compatibility and integration of the various mechanical systems. Each subsystem, from the drivetrain to the intake rollers, was modeled, and their interactions were optimized through multiple iterations to ensure smooth operation. This step was critical in achieving a robot that performed seamlessly on the field.

A significant part of our development process was focused on the flywheel mechanism. After selecting the flywheel as our shooting system, we performed a detailed projectile motion analysis to fine-tune its operation. By modeling the physics of disc trajectories and adjusting variables such as motor speed and the angle of release, we optimized the flywheel for consistent, high-precision shooting. This allowed our robot to score in the high goal effectively, a crucial part of the game.

Our journey also included applying problem-solving strategies to improve component reliability, as seen in our work on the shooting mechanism and pneumatic systems. The iterative process led to several improvements that not only enhanced the performance but also ensured the robustness of our design. This continuous iteration helped us achieve consistency and precision, which were key to winning major awards.

Throughout the season, our robot and design approach were recognized on multiple levels. We were awarded the Design Award at the VEX Worlds Championship, which highlights excellence in the ideation, development, and functionality of robotic components. We also earned the Design Award at the Kalahari Signature Event and took home the National Championship title, demonstrating our team's innovative approach and technical expertise. Our ability to consistently follow a disciplined design process, from CAD modeling to flywheel optimization, ultimately led to our success on the world stage.

View all of 81Y Cypher's Awards and Accomplishments : 81Y Awards and Accomplishments

During my junior year of high school, I founded Mei Cha, a bubble tea business that quickly gained popularity by offering refreshing and culturally enriching beverages at various community events in the Greater Chester County area. As the CEO and founder, I oversaw every aspect of the business, from financial management and HR to marketing, public relations, and operations. My team and I successfully managed the company, bringing Mei Cha from a pop-up operation at local events to opening a brick-and-mortar location during my senior year. This transition allowed us to maintain consistent operations while expanding our reach and creating deeper connections with our customers. Mei Cha emphasized high-quality, customizable drinks, which helped solidify our reputation and allowed us to stand out in a competitive market.

As CEO, I played a critical role in developing and executing the vision for Mei Cha on a daily basis. I managed project timelines, marketing initiatives, and customer service, ensuring that our team delivered a consistent and high-quality product. By leveraging social media marketing and guerilla campaigns, I helped drive growth and increase brand recognition, particularly among our target demographic of young adults aged 13 to 26. Mei Cha's ability to remain agile and adapt to changing market trends was a key factor in its success, helping us expand from events to a more permanent business model.

In the following year, Mei Cha evolved into the Lemon Scholars, a business focused on selling lemonade at large fairs with the goal of raising money for college. As a co-founder, I once again took charge of the business operations, applying my previous experience in entrepreneurship to ensure the Lemon Scholars became a hit. The combined success of Mei Cha and Lemon Scholars led to over $50,000 in total revenue, demonstrating our ability to build and scale successful ventures. This new venture allowed me to continue honing my entrepreneurial skills and provided a scalable business model that brought in steady revenue during peak fair seasons.

Through both ventures, I gained extensive experience in strategic planning, marketing, financial projections, and team management, further enhancing my expertise in business development and entrepreneurship.

I developed the Thermodynamic Properties Calculator as both a MATLAB desktop application and a web app using React and Flask, combining my skills in scientific computing and web development to handle complex thermodynamic tabulations.

In the MATLAB version, I used MATLAB App Designer to create an intuitive interface, allowing users to calculate properties for substances like water, refrigerants, and ideal gases. I implemented interpolation for property lookups, managed various thermodynamic states, and ensured high-precision calculations. The program’s design is modular, with separate functions for each calculation type and robust error handling for reliability.

For the web version, I used React for the frontend and Flask with Pandas for the backend to bring the tool online. The frontend follows responsive design principles for a user-friendly experience, while the backend uses Pandas for fast data processing and calculations. This architecture allows for quick property lookups and efficient interpolation. Both versions demonstrate my expertise in software design and UI development. This dual approach showcases my versatility in scientific and web platforms, making complex calculations accessible through easy-to-use applications while maintaining consistent functionality for a broad range of users.

Visit the Github Repository Here : Github Repository