•Created a project plan with Dr. Wang including project schedule, project costs, and a materials characterization strategy.•Formulated a piezoelectric-epoxy composite for paint-based application. Properties were optimized via trial-based experimentation and design reviews. Applied electric field for dipole alignment and a measurable piezo effect.•Designed components in Solid Works and built experimental apparatus to demonstrate proof-of-concept sensor. •Assisted industry to demonstrate the effectiveness of piezo-ceramic material in caustic solution within a short deadline. •Develop testing processes and safety measures to verify mass loss by prolonged exposure to an agitated caustic solution.•Created test reports summarizing test methods, safety measures taken, and evaluation of test performance data.

Guide and instruct students in the handling of material testing apparatus as well as the gathering of statistically significant data.