1. Filament Winding Machine P09226 Budget Presentation

2. P09226 Goals: – Build Composite Filament Winding Machine – Produce composite tubing – Test product, compare with analytical data Benefits: – Support Formula and Baja teams with composite implementation – Use as lab equipment for Composites course – Learning tool for students

3. System Design

4. Raw Materials 1.Fibers $40-$400 - Fiberglass $1/lb vs. Kevlar $10-15/lb - Soller Composites - Suggested amount of 40-45 lbs. - Less fraying than carbon fiber - Need masks, gloves 2.Resins $350-$400 - Fiber determines resin - Fiberglast/Mertons/US Composites - 5 gallon drum - Includes pump costs 3.Hardener $100-$125 - Time/Temp/Resin determines hardener - Cheaper hardeners tend to yield faster pot lives (restrains design)

5. Creel 1.Single Spool -Minimal raw material cost -Extremely long production time 2.Multiple Spool $50-$75 -Decreases production time (Crucial due to resin pot life) -Requires additional design and raw materials a.Angle and hardware for stand -McMaster Carr b.Delivery Combs/rings -Waiting on pricing c.Multiple Tensioners -Varies with type

6. Resin Bath 1.Drum Type Resin Bath $200 - Chemically Resistant Bin $15-$25 - 3-4 Idler Rollers (Urethane) $15 each - Rubber “Drum” $50 - Doctor Blade $5-$10 - McMaster Carr - Benchmarked at McClean Anderson $4,014 2.Fiber Dip Type Resin Bath $150 - Chemically Resistant Bin $15-$25 - 5-6 Idler Rollers (Urethane) $15 each - McMaster Carr - Benchmarked at McClean Anderson $3,917

7. Sensors 1.Proximity Sensor $1.99 - per unit per order of 1000+ units - Freescale MC33794 - Industrial, Automotive Applications - Non-contact proximity sensor for control of feed-eye travel 2.Hall Effect Sensor $2.40 - per unit per order of 1000+ units - Analog Devices - Detect rotation of mandrel 3.Overstock distributor in Rochester

8. Temperature Measurement 1.Thermocouple Probe $5 - $25 -Sears -Monitor resin temperature 1.Thermocouple Sensor $100-$250 -Monitor resin temperature 2.Thermometer $5-$25 -Monitor resin temperature

9. Ventilation 1.Duct $100 -Drill Spot -To vent vapors from resin 2.Fans $6-$18 -Radioshack 3.Ventilation Fan $150-$300 -Specific to need, but much higher cost 4.Insulation $10

10. Maintain Tension 1.Variable Spring Rate $50 - Rotary Tensioner - Up to 30lbs, adjustable by angle - Need pulley - Fenner Drives RT1000 series - One attachment point 2.Rubber Bushing $45 - Dependent on spool size, ½”, ¾”, 1” OD - 3 @ approx $15 ea - McMaster Carr - Less Control 3.Torturous Path $140 - Multiple Rollers - 4 @ approx $35 ea - Osbourne Int. 1” dia. - Can reduce cost by being used with bath - Multiple attachment points

11. Tension Measurement 1. Strain Gage - Roller(s) w/ strain gage - Continuous loop feedback - Waiting on pricing 2. Load Cell - Roller(s) w/ load cell - Continuous loop feedback - Waiting on pricing 3.Small Force Gage $200 - Jonard - MSC

12. Mandrel Material 1. Aquacore - $ - Soluble w/water - Some available already 2. Metal - $15 - Difficult to remove 3. Plastic - $10 - Chemical bonding considerations

13. Motors 1.AC Motors $78-$250 2.DC Motors a.Brushed $230 b.Brushless $170-$700 c.Stepper $16-$500

14. Final Est. Budget Raw Mat'l: $500-$600 Creel: $75 Temp Control: $25-$100 Resin Bath: $150-$200 Tensioner: $100-$150 Ventilation: $250-$350 Motor Assy: 2x $500-$700 Mandrel: $10-$15 (Aquacore?) Controller/Control Panel: $150-$200 (Total Range) x (Contingency) = Final Est. Budget $2260 - $3090 x 30% = $3000 - $4020

15. References Raw Materials www.sollercomposites.com www.fiberglast.com www.mertons.com www.uscomposites.com www.mcmaster.com Resin Bath www.mcleananderson.com Sensors www.freescale.com www.analog.com Ventilation www.drillspot.com www.radioshack.com Temperature Measurement www.sears.com http://us.st12.yimg.com/us.st.yimg.com/I/yhst- 19701683355538_2030_667414 Tensioner www.fennerdrives.com www.tensionmeters.com www.jonard.com www.mcmaster.com Mandrel www.acrtucson.com Motors www.inverterdrive.com www.germes-online.com www.orientalmotor.com www.societyofrobots.com Creel www.mcmaster.com