...

Research

...

Concepts for how various materials and parts will assemble together

Foam to seat: Velcro, glue, tape, magnetsDP-420

Cloth to foam: buttons, sewing, Velcro, hooks, tape, magnetssewing and Double-sided tape/3M 78

Cloth to seat: tie, button, sew, hook, Velcro, melt, glue, tape, magnetsDP-420

CF to CF: DP-420

Proof-of-Concept Testing

What sort of testing should we be doing to ensure our chosen materials/manufacturing processes/assembly methods will work on the end-product?

...

Could include ordering samples, testing fastening/joining methods, testing assembly procedures.

Seats Manufacturing

Seats Cushions:

Materials:

·        Neoprene 1/2 in thickness foam

·        Polyethylene open cell high density 1 in foam

·        Meidong Nano Tape Double Sided Super High Viscosity Tape Roll or Polystyrene Foam Insulation 78 Spray Adhesive

·        Scissors

·        2 part epoxy (DP-420)

·        3M SJ3550 Dual Lock Recloseable Fastener

Manufacturing:

1. Using the 2 part epoxy (DP-420) (making sure to pull the neoprene over the edges of the seat back) adhere to seat back and seat pan

2. Adhere the polyethylene closed cell to the neoprene with the tape/spray (the foam will need to be pressed down with a weight and left for 1-3 hours to dry). The tape/spray should be applied to both sides of the cushioning.

3. Place the open cell on the areas that need to be padded based on the mockup (again use the tape/spray to secure the soft open cell to the closed cell)

4. The contouring of the foam will need a jig

How to construct the jig:

Seat Pan:

Materials:

·        Carbon fiber flat panel from the flat panel (2 layer carbon fiber each side)

·        Carbon fiber to carbon fiber adhesive

·        Neoprene foam

·        Polyethylene foam

Manufacturing:

1. Cut from the panel into the shape needed with cnc

2. Cut foam to fit inside the seatback (please see assembly doc)

3. Adhere foam together with the tape/spray (will need to be clamped down)

4. After the foam has uncompressed adhere it to the seat back with DP-420 (the carbon fiber will need to be cleaned with acetone and sandpaper before using the adhesive)

5. Adhere extra support to the foam with the tape/spray (side cushioning for butt and legs)

Seat back:

Materials:

·        Carbon fiber 6.2oz x 50” Twill Carbon

·        MDF mold from wood

·        Cnc routed for the cuts (cnc for the mold and the cutting of the hole for the inserts))

·        Peel/wax

·        Nomex (1/4 in)

·        Tacky tape

·        Vacuum bag

·        Resin

·        Neoprene foam

·        Polyethylene foam

Manufacturing:

1. Take CAD mold and CNC them

2. Line mold with wax (anti-peeler)

3. Take the carbon fiber and (2 layers) and vacuum bag (about 24-48 hours)

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

5. Place 1 layer of Kevlar onto the nomex in the shoulder area (between head and top of shoulder)

6. Place the final 2 layers of carbon fiber and vacuum /back again (about 24-48 hours)

7. Slowly remove from the mold

8. Cut foam to fit inside the seatback (please see assembly doc)

9. Adhere foam together with the tape/spray (will need to be clamped down)

10. After the foam has uncompressed adhere it to the seat back with DP-420 (the carbon fiber will need to be cleaned with acetone and sandpaper before using the adhesive)

11. Adhere extra support to the foam with the tape/spray (side cushioning, bolsters, lumbar, and headrest)

Seat Supports:

Materials:

·        Carbon fiber flat panel

·        DP-420

Manufacturing:

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

2. Adhere all flat panels to each other using DP-420

3. Attach to the bottom panel using DP-420

Flat Panels:

Materials:

·        Carbon fiber flat panel (2 layers of cf on each side)

·        DP-420

Manufacturing:

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

2. Adhere all flat panels to each other using DP-420

3. Attach the foam to pan using DP-420

4. Attach to the bottom panel using DP-420

Ballast:

Materials:

·        Carbon fiber flat panels (1 layer of cf per side for the ballast)

·        DP-420 for cf to cf adhesive

·        90 degree angle brackets

·        SmartStraps 14 ft. 1500 lb RatchetX Ratchet Tie Down

Manufacturing:

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

2. Adhere all cf panels with DP-420

3. Drill holes in the side panel and in the lid

4. Align 90 degree brackets and adhere onto the lid

5. Glue bolt on the inside of the ballast and secure

Inserts:

·        3D printer

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

Manufacturing:

1. Take mold from CAD

2. Put into machine