Next Generation Carbon Fiber Airframe Team Progress Report David Edwards, Alex Kollen, Danny Johnson, Alex Chan, Nicholas Cho March 1, 2016

Background PSAS - Portland State Aerospace Society

Background 2013 PSAS capstone team - Manufacturing Process Issues Requires a lot of practice Wrapping shrink tape Difficult to cut sheets to exact length and layup Surface finish is too rough for mach3 (LV4)

Design Goals Primary Objectives Design and strength test a 14 inch diameter rocket Obtain a smoother outer surface finish Maintain as much of the weight loss as possible At least 50% weight loss over aluminum Optimize manufacturing process Current process is too complicated, skill based and time consuming for untrained operators to manufacturers to obtain satisfactory results.

SolidWorks Remodel

FEA Analysis Compression - Extremely strong Tension - Relatively Weak Preliminary FEA Analysis - Further bending and Torsional to come Compression - Extremely strong Tension - Relatively Weak

Pending Design Solution Vacuum Pull Through Pros Less skill oriented and more repeatable than current layup method External surface finish is reliant on mold finish only Cons Skill oriented in obtaining proper seals Expensive

Pending Design Solution Material Quantity Cost Stretchlon® 800 Bagging Film 60” by 60 Yards $ 228.00 Breather (4oz) $ 261.00 Release Film 60” by 30 Yards $ 465.00 Puddy 4 X 25ft Roll $ 31.80 Flash Tape (Roll) 1 Roll $ 29.95 Through Bag Vacuum connector 2 $ 79.90 Vacuum Gauge 1 $ 39.95 Total $ 1135.60

Pending Design Solution Clam Shell In conjunction with a product called AirPad HTX which will be used to make a flexible mandrel used with the clam shell and vacuum pull through design solutions

Current Problem Epoxy Still need adhesive sheeting - limiting factor More expensive than originally expected How to proceed from here May have to use fiberglass and cheaper epoxy in order to proof the rings and surface finish process. Spending our limited funds wisely, likely on aluminium and 3M products.

Questions?