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Ivan Cao (Deactivated)

Ivan Cao (Deactivated)

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Find the main material for the cover

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Catamaran Cover Materials/Manufacture/Assembly Concepting

Research material specifications

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Hand to Renzo by the end of the week

Clean up detailed design research

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Check with Adrian on numbers

Manufacturing research

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Mold research

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Waterproofing

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Finishing

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Might not be as important EVERYTHING IS IMPORTANT - DAPHNE

Item list of parts and how they will be manufactured (roughly)

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Main material sourcing and pricing

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Foam molds

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Manufacturing research

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Infusion equipment

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Manufacturing plan

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titleMaterial strength of Acrylic (Plexiglas), PETG 3D printed plastics.

[1] Acrylic
Yield Strength: 64.8 - 83.4 MPa (Average value: 75.4 MPa)
Young’s Modulus: 2.76 - 3.30 GPa

Flexural Modulus: 2.96 - 3.30 GPa
Flexural Yield Strength: 98.0 - 125 MPa (Average value: 109 MPa)

[2] PETG
Yield Strength: 28.3 - 58.6 MPa
Young’s Modulus: 1.10 - 20.3 GPa (Average value of 2.65 GPa)

Flexural Modulus: 1.17 - 2.76 GPa
Flexural Yield Strength: 39.2 - 88.9 MPa (Average value of 69.5 MPa)

In short, Plexiglas is a strong enough viable alternative for the side walls of the cover.

Gel-coat
Protective finishing layer for composite surfaces.
Leaves a hard smooth surface good for sticking on adhesive.
Requires sanding and buffing for a smooth surface.
If painting the cover, apply gel-coat first then paint over it.

Source:
[1] http://www.matweb.com/search/datasheet.aspx?bassnum=O1303
[2] http://www.matweb.com/search/datasheet.aspx?matguid=4de1c85bb946406a86c52b688e3810d0

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titleFiberglass/Foam core/Resin cost

Total surface area: 5.19m^2
Widest part of cover: 0.7112m
Required area of cloth: 23m^2 (2 layers each side plus 10% for headroom)

Would need to order 26 yards
Priced at $11.55 per yard
Approx price: $300 (before applicable taxes and discounts)
Link: https://shop.compositescanada.com/#/product/FJ09-7725-38-LY

Foam:
One sheet of foam cut into 4 thinner sheets covers 5.946m^2

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Would need to order 1 sheet
Priced at $42.6 per sheet
Approx price: $42.60 (before applicable taxes and discounts)
Link: https://shop.compositescanada.com/#/product/U720-100-48

Resin:
Ratio by weight is 2.5:1 resin to fiberglass
Fiberglass is sold by weight per square yard
Total area 20.76m^2 or 24.83 yard squared
Total weight in cloth: 24.83*8.8oz = 218.504oz. Around 6.2kg
Would require 15.5kg (34.17lb) of mixed resin.

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titleFoam for mold

Solid insulation foams from local hardware stores are good mold making material.
Can glue multiple sheets together to increase thickness for desired mold shape.

Volume per sheet: 2304 sq. in
Front right and left wall: 182.22 sq. in
Rear right and left wall: 289.66 sq. in
Front lid: 790.32 sq. in
Rear lid: 2521.2 sq. in
Total mold volume: 4255.27 sq. in
Requires 2 sheets: $40 total

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