DRI: Aidan Lehal Salman Rasheed
Just add design decisions, considerations, and updates etc. Treat this as a paper trail.
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Project Requirements
Criteria:
Base needs to be sturdy
Ribs need to be (perfectly) parallel to each other, and perpendicular to the base in order to ensure curvature accuracy
Limit cost/try to use material already in the bay
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Ribs are being made out of metal
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Design Iterations
Aluminum Pipes Base
Base Cad: Using pipes already in the bay, a simple frame to support and hold the ribs was crafted. The tubes are 1.25” in diameter and aluminum.
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The tubes (grey circular) will be welded together using a jig, and the ribs (Orange) will be welded with the same jig.
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Welding Jig
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Welding jig supporting horizontal pipe while aligning rib at designated location.
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Welding Jig supporting two tubes to create a T joint or corner once welded
MDF Mold:
Made out of MDF, slots for ribs to be placed, with hardstops at the front and back to prevent movement.
MDF does not require welding
MDF base can be reused by removing the ribs from the slots and replacing them with new ones (that fit a different panel)
MDF will have to be purchased
Aluminum Tube Pipe Mold w/ Slots
Made out of tubes pipes as cadded above
Tubes Pipes have slots that allow for ribs to be inserted and removed in the event of recycling a mold
This method uses tube we already have
This method does not require RIB welding
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Sturdy and one shape use, very durable
Requires welding (will need to see what aluminum tubes can withstand) or adhesive
MDF Base
After review of the potential options, an MDF base was chosencadded. The ability to replace ribs for a different mold was an advantage we wanted to utilize. We also did not require any welding or glue of any sort. We would use cutouts in the MDF to position the planks and wood screws to solidify their position.
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Updated base w outer and inner brackets + screw holes:
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Manufacturing Plan for MDF Base:
CNC out rib, side, and hard-stop planks
Use a 90 degree angle clamp, or two clamps and a square to screw a bracket into a side plank and hard-stop plank. Repeat for all four corners to form a rectangular frame.
Screw a bracket onto either side of a rib plank, repeat for all the rib planks.
Use the 90 degree angle clamp to screw in the rib planks to the side planks, as well the a bracket on each side of the rib planks to the side plank.
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8 Rib Planks (cut to length with slots)
2 Side Planks
2 Hard-stop Planks
20 Aluminum Brackets (https://www.homedepot.com/p/Everbilt-2-1-2-in-Zinc-Plated-Double-Wide-Corner-Brace-8-Pack-12434/315016358 )
>150 3/4” Wood Screws
Impact Drill/Drill/Screwdriver
90degree Clamp/Blocks
Shims the same height as the clamp/blocks
Aluminum Extrusions Base
Pros:
Reusable
Durable
Little machining required
Easily adjustable
Welding ensures stiffness, and perpendicularity for the ribs
An aluminum extrusion base will be held together by the concealed corner brackets.
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The ribs would be welded to brackets, which are set to the desired location beforehand and tightened in place.
The ribs can be welded at multiple bracket points, each colour represents another racket welded to the aluminum extrusions below. Depending on the amount of welded brackets, aluminum extrusion crossmembers can be added or removed as needed.
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