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Research

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o   Start CAD for the MDF mold (with a question about how to do the bottom that touches the floor)

Manufacturing detailed steps

Mockup:

Materials:

·        Wood (plywood)

·        Foams (all three)

Manufacturing:

1. Use ¼ in wood an place in the mockup

1. Place the foam and ask people

1. Ask about seat angle

1. Ask about the amount of padding

1. Adjust seat angle as needed

Seats Cushions:

Materials:

·        Neoprene ¼ in thickness foam

·        Polyethylene closed cell high density ½ in foam

·        Polyethylene open cell high density ½ in foam

·        A & E cement

·        Power knife

·        2 part epoxy

·        Mushroom Velcro stuff

Manufacturing:

1. Using the 2 part epoxy and the neoprene glue the layer on top of the carbon fiber seat back and the carbon fiber seat pan (making sure to pull the neoprene over the edges of the seat back)

1. Contour the polyethylene seat foam using a jig and a power knife (based on the predetermined mockup dimensions)

1. Add the polyethylene closed cell to the neoprene with the cement (the foam will need to be pressed down with a weight and left for 1-3 hours to dry). The cement should be applied to both sides of the cushioning. The ballast and the bolsters will also need a layer of foam (do this with the 2 part epoxy)

1. Place the open cell on the areas that need to be padded based on the mockup (again use the cement to secure the soft open cell to the closed cell)

Seat Pan:

Materials:

·        Carbon fiber flat panel from the flat panel

·        4 different panels: 2 front 2 rear (for dimensions see CAD)

·        Carbon fiber to carbon fiber adhesive (WHAT IS THIS)

Manufacturing:

1. Cut from the panel into the shape needed (

ask if this is possible)

Seat back:

Materials:

·        Carbon fiber pre-preg (HOW MUCH)

·        MDF/CNC mold from wood

·        Peel/wax

·        Nomex (1/4 in)

·        Tacky tape

·        Vacuum bag

·        (vacuum and/or oven)

·        Resin

·        Plaster (for filling in molds)

·        1 or 2 molds depending if filling in with plaster is an option (and doesn’t cause any problems)

Manufacturing:

1. Take CAD mold and CNC them

1. Line mold with wax (anti-peeler)

1. Take the pre-preg and make about 2 layers and vacuum bag (about 24-48 hours)

1. Place in the nomex and coat with resin (vacuum bag again) (about 24-48 hours)

1. Place the final 2 layers of pre-preg and vacuum /back again (about 24-48 hours)

1. Slowly remove from the mold

1. For the rear molds it may be possible to fill in the front molds with plaster and reuse the mold that way

Seat Supports:

Materials:

·        Carbon fiber flat panel

·        Carbon fiber to carbon fiber adhesive

Manufacturing:

1. Cut from the flat panel into triangular sections (see CAD for dimensions)

Flat Panels:

Materials:

·        Carbon fiber flat panel

·        Carbon fiber to carbon fiber adhesive

Manufacturing:

1. Cut from the flat panel into triangular sections (see CAD for dimensions)

Ballast:

Materials:

·        Carbon fiber flat panel

·        Carbon fiber to carbon fiber adhesive

Manufacturing:

1. Cut from the flat panel into triangular sections (see CAD for dimensions)

Inserts:

·        3D printer

·        PC-ABS plastic with solid fill and standard should be ok

Manufacturing:

1. Take mold from CAD

1. Put into machine