1 st Petal Prototype Fabrication completed October 27, 2008

1 st Prototype Components

Weights Weights of components are summarized below End-closeouts were aluminum for this prototype, would not be the case for real object (carbon material) ItemWeight(g) Carbon fiber facings61 Honeycomb16 POCO foam27 SS Tube32 Epoxy30 CGL30 Carbon tubes15 Subtotal211 Closeouts+pins43 TOTAL253

2 nd Prototype – Proposed Changes Add a bit more honeycomb(gap to side carbon tubes too large) Grind honeycomb flat before gluing to facing. Grind honeycomb to thickness after gluing one side to facing to improve thickness uniformity. Demonstrated on prototype piece Small increase in length of POCO foam(right up to outer closeout) Bond POCO foam/tube assembly to facings with Hysol 9396/30%(or more) BN instead of CGL-7018 => make rigid connection between foam and facing. Use bond-line control (the equivalent of 75 micron little shims) Modify U-section of POCO foam to allow for tube contraction as result of the above Reduce size of closeouts Bond closeouts with bond line control(glass beads) Decide about precision location of carbon tubes – try it on this prototype? Some minor tooling modifications to make assembly easier Currently scheduled for assembly Dec. 1-12