Versions Compared

Version Old Version 36 New Version Current
Changes made by

Ivan Cao (Deactivated)

Ivan Cao (Deactivated)

Saved on

Key

  • This line was added.
  • This line was removed.
  • Formatting was changed.

Ownership

...

Task

Status (type “/status”)

Notes

Find the main material for the cover

Status
colourGreen
titlecompleted

Catamaran Cover Materials/Manufacture/Assembly Concepting

Research material specifications

Status
colourGreen
titleCompleted

Hand to Renzo by the end of the week

Clean up detailed design research

Status
colourGreen
titleCOMPLETED

Check with Adrian on numbers

Manufacturing research

Status
colourGreen
titleCOMPLETED

Mold research

Status
colourGreen
titleCOMPLETED

Waterproofing

Status
colourGreen
titleCompleted

Finishing

Status
colourYellow
titlein progress

Might not be as important EVERYTHING IS IMPORTANT - DAPHNE

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

Status
colourGreen
titleCompleted

Main material sourcing and pricing

Status
colourGreen
titleCompleted

Foam molds

Status
colourYellowGreen
titlein progresscompleted

Manufacturing research

Status
colourYellow
titlein progress

Infusion equipment

Status
colourYellow
titlein progress

Manufacturing plan

Status
colourYellow
titlein progress

...

Expand
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

...

Expand
titleFiberglass/Foam core/Resin cost

Total surface area: 5.19m^2
Widest part of cover: 0.7112m
Total perimeter length: 549.18in
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

Image RemovedImage Added

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.

Expand
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 cu. in
Front right and left wall: 182.22 cu. in
Rear right and left wall: 289.66 cu. in
Front lid: 790.32 cu. in
Rear lid: 2521.2 cu. in
Total mold volume: 4255.27 cu. in
Requires 2 sheets: $40 total

Image Added

Expand
titleManufacturing equipment

Part(s)

Cost

Supplier

Sealant tape

$7.00 per 25 foot roll ($21.00) for 3 rolls (CC sells them in cases of 40)

https://shop.compositescanada.com/#/product/VATP-AT200Y

Bagging film

$2.77/yd ($27.7) for 10 yards

https://shop.compositescanada.com/#/product/VABF-EL-60-LY

Pump

N/A

Bay

Breather 4oz

$7.60/yd ($26.6) for 3 yards

https://shop.compositescanada.com/#/product/VABR-N4-LY

Peel Ply

$7.00/yd ($35) for 5 yards

https://shop.compositescanada.com/$#/product/VAPP-ES-LY

Epoxy resin

$169.62

https://shop.compositescanada.com/#/product/AE2032-60-X


Manufacturing Plan

Wet layup process

Infusion process
Steps:

  1. Put on PPE equipment. Includes safety glasses, gloves, mask.

  2. Measure and cutout correct dimensions of fabric, foam, process materials (breather, peel ply, bagging film, sealant tape)

  3. Measure out correct amount of resin and hardener and mix

  4. Stick the perimeter with sealant tape and overlap them if needed

  5. Prep the mold surface with release agents

  6. Wet the surface of the mold with mixed resin

  7. Apply first layer of fiberglass and gently dab and brush with more resin until fully wet

  8. Place second layer of fiberglass and repeat step 6

  9. Place core material on top and continue wetting both sides of it

  10. Place the last two layers and wet them completely

  11. Layer on top a sheet of peel ply

  12. Add on breather fabric on top of peel ply

  13. Add some breather near planned placement of vacuum tube

  14. Cover the entire mold with bagging film making sure to stick them onto the sealant

  15. Check for sharp curves and adhesiveness

  16. Insert tubing and fittings around vacuum port on the bag

  17. Connect tubing to vacuum pump and turn on

  18. Adjust to 14psi and leave for several hours to cure