NIU at RVC engineering team repeats as NFPA Challenge Grand Champion

A year ago, the NIU Engineering at RVC (Rock Valley College) team took Grand Champion honors at the National Fluid Power Association (NFPA) national competition in Ames, Iowa.

At the time, it appeared to be a high-water mark, but it turns out the College of Engineering and Engineering Technology (CEET) program was just kicking into gear. Returning last month to the 2025 Fluid Power Vehicle Challenge, this year's Huskie team took first place in the sprint race and endurance race competitions as well as third place in the efficiency race.

On top of those outcomes, the Huskies received the Judges Choice Award for Workmanship and the Final Presentation award.

It all added up to a dominant Grand Champion performance, as NIU tallied 26.19 points, well ahead of runner-up Cleveland State University (22.62 points) and third-place Florida A&M University-Florida State University (21.05 points).

“It was an outstanding and thrilling experience,” said Ghazi Malkawi, the team’s instructor and program advisor for NIU at RVC. “They wowed me and the audience; it was truly remarkable.”

“By studying last year's design, they identified key improvements, including implementing a wider range of gear ratios, a 30-pound weight reduction, and revamping the layout and plumbing, which helped to increase efficiency by 15%,” Malkawi added. “Without the new changes and a commitment to improving their performance, they would not have won this year, especially since other teams were closing in on NIU's last performance.”

The team was a major attraction on May 2nd at CEET’s Senior Design Project Showcase, held at the NIU Convocation Center, drawing interest from numerous middle school, high school and college students, along with other members of the public.

In addition, the team was featured on WTVO, a Rockford television station.

Jaron Benson, president of the Fluid Power Club, managed the project and helped design hydraulic schematics, calculated sizing components, and designed and programmed the controls for the entire system.

“This experience exposed me to the fluid power industry and helped me to develop practical skills that I can apply to a wide range of applications from mobile to industrial,” Benson said. “Specifically, it was interesting to learn about regenerative breaking and how hydraulics can be used to recuperate lost energy within a system.”

Another team member, Rakan Abu Al Rub said the yearlong experience underscored “the importance of adaptability and problem solving in real-world engineering,” along with teamwork and communication.

His role included helping source and implement the gear systems for the motor and pump, as well as helping redesign the stock frame.

“Even with detailed planning, unexpected challenges came up, and success depended on how quickly and effectively we could find solutions,” Abu Al Rub said. “Working under tight timelines leading up to the competition especially reinforced the value of staying flexible and working collaboratively under pressure.”

With over a dozen years of competitive riding experience, from go-karts to asphalt super late models, Max Kahler was a natural fit as the team's main rider. "It was fun to do the mechanical work and fabrication and figure it all out together as a team and then go and execute at the competition," said Kahler.

Composed entirely of seniors majoring in mechanical engineering, the team that worked on the hydraulics system were Benson, Arthur Kozlowski, Forrest Arroy, Jacob Connors and James Simmons. In addition to Abu Al Rub and Kahler, Cin Suum was part of the bicycle frame team.
Supporting Malkawi’s oversight was the team’s teaching assistant, Michael Larsen.

The standout showing was the culmination of much hard work, Malkawi noted, as the team met every Monday throughout the two semesters and sometimes on Thursdays as the competition neared.

The team completed the computer aided design (CAD) assembly, as well as the design of electrical and hydraulic circuits. They also performed simulations, including structural analysis and calculations for system analysis, before ordering parts and beginning the assembly process.

One key was the team’s meeting all the required deadlines and finishing the bicycle build-out two weeks ahead of race day.

“That gave them enough time to test different efficiency parameters and get familiar with riding the vehicle,” Malkawi said.

Other colleges that competed were North Carolina A&T, Colorado School of Mines, Ohio University, Purdue University, Texas A&M and the University of Louisiana at Lafayette.

Team members expressed gratitude to Danfoss employees for technical support throughout the year, as well as to local businesses that provided support: MI Motion, Parker's Cylinder and Accumulator Division, Pneumatic Cylinders and Couplers, Rockford Bicycle Co. and Weldments Inc.

At the heart of engineering is continual improvement, so there’s no way the next crop of seniors will rest on the program’s two-year run of extraordinary success. In 2026, look for the Huskies to aim for a third consecutive championship.

In 2016, the NIU Engineering Program at Rock Valley College in Rockford was formed. Known as NIU @ RVC, it was created in collaboration with RVC and regional industry partners to foster talent in the Rockford area. Students can earn their associate degree in engineering from RVC and go on to earn a bachelor’s in engineering from NIU, all on the RVC campus in Rockford.

NIU College of Engineering and Engineering Technology (CEET) provides affordable access to a world-class engineering education. Our fully accredited programs emphasize hands-on experience, with small classes taught by experienced, dedicated faculty that help a diverse array of students explore and ignite their passions in bachelor’s, master’s and doctoral degree programs. Learn more by visiting our website.