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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?

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

Seats Manufacturing

·         Seat pan/leg pan/supports: cut from flat panels

o   Need calculations on how strong the panels needs to be (both with the supports and without) (thickness that the panel needs to be)

·         Back rest:

o   Pre-preg with an MDF mold (there may be a slight problem with the way the bottom that touches the floor needs to be cut (it is not a radii at the moment its very sharp but I think it won’t matter because we have triangular supports)

§  Need calculations to see how thick the panel needs to be

·         Foams:

o   CNC hot wire cutting for the polyethylene for complex concave (ask them if the wire will do neoprene there website does not say that this is a type of foam that they cut)

o   Foam to foam is A & E contact cement (used in cosplay outfits if it good enough for them then it’s good enough for me)

o   Foam to cloth is A & E contact cement

o   Foam to seat 2 part epoxy

o   Foam should wrap around the corners of the seat back and seat pan to minimize injury of having exposed CF panel that is sharp

o   Neoprene, High density polyethylene closed cell, and polyethylene open cell (also High density)

·         Materials/cloth

o   Mesh (backpack type)

o   Power mesh

o   Neoprene

·         Inserts

o   Plastic inserts (simple in shape maybe able to just use the machine shop) general shape is a rectangular prism with a rim

o   If we tweak the dimensions we could just buy them off the shelf

·         Ballast

o   CF for the flat panels over lined the outside with foam to stop sharp edges

o   Flat panels just cut and attach with epoxy

o   For the pin mechanism maybe glue another material up there so it has something to drill into (stainless steel pivot hinge rotation they cost about $30 for 2)

o   Attaching panels should still be epoxy

o   Hold the ballast box in the box with the mushroom/Velcro thingy

o   Next steps: How to hold the swinging lid in place???

      Next steps:

o   Get calculations for the seats thickness (for all components)

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 1/2 in thickness foam·        Polyethylene closed cell high density ½ in foam

·        Polyethylene open cell high density ½ 1 in foam

·        A & E cement·        Power knifeMeidong Nano Tape Double Sided Super High Viscosity Tape Roll or Polystyrene Foam Insulation 78 Spray Adhesive

·        Scissors

·        2 part epoxy (DP-420)

·        Mushroom Velcro stuff3M SJ3550 Dual Lock Recloseable Fastener

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 (DP-420) (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 adhere to seat back and seat pan

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

3. Place the open cell on the areas that need to be padded based on the mockup (again use the cement 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 ·        4 different panels: 2 front 2 rear (for dimensions see CAD(2 layer carbon fiber each side)

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

·        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 (

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1. the carbon fiber will need to be cleaned with acetone and sandpaper before using the adhesive)

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

Seat back:

Materials:

·        Carbon fiber pre-preg (HOW MUCH)6.2oz x 50” Twill Carbon

·        MDF /CNC 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·        (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)Neoprene foam

·        Polyethylene foam

Manufacturing:

1. Take CAD mold and CNC them

2. Line mold with wax (anti-peeler)

3. Take the pre-preg and make about 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 pre-preg carbon fiber and vacuum /back again (about 24-48 hours)

7. Slowly remove from the moldFor the rear molds it may be possible to fill in the front molds with plaster and reuse the mold that way

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

·        Carbon fiber to carbon fiber adhesiveDP-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 ·        Carbon fiber to carbon fiber adhesive(2 layers of cf on each side)

·        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 the foam to pan using DP-420

4. Attach to the bottom panel using DP-420

Ballast:

Materials:

·        Carbon fiber flat panel

·        Carbon fiber to carbon fiber adhesive

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 triangular 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

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Manufacturing:

1. Take mold from CAD

2. Put into machine