Transportation infrastructure is an integral part of the world’s overall functionality; however, current transportation infrastructure has aged since it was first developed and implemented. Consequently, given its condition, preservation has become a main priority for transportation agencies. Billions of dollars annually are required to maintain the United States’ transportation system; however, with limited budgets the prioritization of maintenance and repairs is key. Structural Health Monitoring (SHM) methods can efficiently inform the prioritization of preservation efforts. This paper presents an acoustic monitoring SHM method, deemed tap testing, which is used to detect signs of deterioration in structural/mechanical surfaces through nondestructive means. This method is proposed as a tool to assist bridge inspectors, who already utilize a costly form of SHM methodology when conducting inspections in the field. Challenges arise when it comes to this method of testing, especially when SHM device deployment is done by hand, and when the results are based solely upon a given inspector’s abilities. This type of monitoring solution is also, in general, only available to experts, and is associated with special cases that justify their cost. With the creation of a low-cost, cyber–physical system that interrogates and classifies the mechanical health of given surfaces, we lower the cost of SHM, decrease the challenges faced when conducting such tests, and enable communities with a revolutionary solution that is adaptable to their needs. The authors of this paper created and tested a low-cost, interrogating robot that informs users of structural/mechanical defects. This research describes the further development, validation of, and experimentation with, a tap testing device that utilizes remote technology.

Sensors have recently become valuable tools in engineering, providing real-time data for monitoring structures and the environment. They are also emerging as new tools in education and training, offering learners real-time information to reinforce their understanding of engineering concepts. However, sensing technology’s complexity, costs, fabrication and implementation challenges often hinder engineers’ exploration. Simplifying these aspects could make sensors more accessible to engineering students. In this study, the researcher developed, fabricated, and tested an efficient low-cost wireless intelligent sensor aimed at education and research, named LEWIS1. This paper describes the hardware and software architecture of the first prototype and their use, as well as the proposed new versions, LEWIS1-β and LEWIS1-γ, which simplify both hardware and software. The capabilities of the proposed sensor are compared with those of an accurate commercial PCB sensor. This paper also demonstrates examples of outreach efforts and suggests the adoption of the newer versions of LEWIS1 as tools for education and research. The authors also investigated the number of activities and sensor-building workshops that have been conducted since 2015 using the LEWIS sensor, showing an increasing trend in the excitement of people from various professions to participate and learn sensor fabrication.