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

2. Background
PSAS - Portland State Aerospace Society

3. 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)

4. 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.

5. SolidWorks Remodel

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

7. 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

8. Pending Design Solution
Material
Quantity
Cost
Stretchlon® 800 Bagging Film
60” by 60 Yards $
Breather (4oz) $
Release Film
60” by 30 Yards $
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 $

9. 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

10. 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.

11. Questions?