Throughout the fall 2024 semester, Gregory Pratt, a senior undergraduate mechanical engineering student in the University of Notre Dame’s College of Engineering, focused on making an existing bracket for a collapsible staircase handrail easier to produce and more secure to use.

Pratt, an intern with Industry Labs at the University of Notre Dame, was paired with Ameri-Can Engineering, a well-established innovator in the trailer manufacturing industry focusing on restroom and shower units. Ameri-Can Engineering’s team is based in nearby Argos, Indiana.

Ameri-Can’s restroom and shower trailers are in high demand following environmental disasters. For instance, after a hurricane or wildfire, when the usual facilities have been destroyed or damaged, the trailers can help fill the gap until the facilities are repaired or replaced.

Each trailer has a deployable staircase, for users to access the trailer’s facilities, that folds up while the trailer is in transit and can be secured safely into position.

Pratt was tasked with improving the handrail retention bracket. The original bracket securing the staircase’s handrail in place was made of steel, and a redesign was requested to reduce cost and effort in production. Finally, the original bracket lacked an easy and intuitive way to store its components during transit, which could result in lost parts over time.

"This project gave me the freedom to further explore my creativity, which was incredibly rewarding,” said Pratt. “Having the ability to quickly translate my ideas into physical prototypes utilizing additive manufacturing allowed for rapid iteration and refinement of the design, ensuring proper functionality as well as an optimized design to be implemented in Ameri-Can’s trailers."

Akash Praharaj, engineering project manager with enFocus and Industry Labs, connected and oversaw Pratt’s work with the company.

“This was an exciting opportunity to include a talented, undergraduate engineering student to help solve a design issue for a regional manufacturer,” said Praharaj. “Gregory was able to utilize multiple assets on campus, including the IDEA Center’s Innovation Lab and the Engineering Innovation Hub, to design, prototype, and test his design before it was presented to the company.”

Pratt, with Praharaj’s guidance, worked to design a bracket that could be 3D printed. He also incorporated the metal mounting bracket needed to make it secure. The design could be created more quickly without the complexity that held up the original design’s production. Finally, the design Pratt presented to Ameri-Can would secure the locking mechanism in place with the bracket so all of the multiple parts stayed together in transit.

"The thoughtfulness and ingenuity displayed in the designs were truly impressive, and they have inspired our team to think more creatively about our problem,” said Keegan Campbell, chief operating officer of Ameri-Can Engineering.

Pratt will be graduating in May with his degree in mechanical engineering from the College of Engineering at the University of Notre Dame. His experience working with iNDustry Labs and Ameri-Can Engineering has inspired him to explore opportunities in the South Bend - Elkhart region.

Have opportunities in the region for the Notre Dame 2025 class? Send them to our Jean Crumlish, program operations manager at iNDustry Labs, at jcrumli2@nd.edu, who leads efforts in promoting regional career opportunities to the Notre Dame network.

About iNDustry Labs

iNDustry Labs at the University of Notre Dame helps companies unlock a competitive advantage for the South Bend - Elkhart Region. iNDustry Labs is a proud anchor of the region’s Labs for Industry Futures and Transformation (LIFT) initiatives.

Learn more by visiting industrylabs.nd.edu.

Contact: Christina Clark, Research Communications Specialist

iNDustry Labs | Notre Dame Research | University of Notre Dame

cclark26@nd.edu | 574.631.2665

Originally published by Christina Clark at industrylabs.nd.edu on March 25, 2025.