Ownership

Research

Interesting research, images, links, recap of regulations, etc.

• video on manufacturing process of a carbon fibre based seat Status Racing - The Making of a Ring Seat 

• video on pouring a foam insert for a bucket seat Making A Custom Foam Insert for the Race Seat

https://www.team-bhp.com/forum/technical-stuff/9521-pics-carbon-fiber-seat-how-handmade-fsae.html

https://www.instructables.com/id/Simple-methods-for-molding-fiberglass-and-carbon-f/

https://www.youtube.com/watch?v=zzQlj0zZiC4

https://www.youtube.com/watch?v=3q4GzggRumI

https://www.youtube.com/watch?v=AZasTVWY34A

https://www.youtube.com/watch?v=76E-A357ZSg
https://www.intechopen.com/books/textiles-for-advanced-applications/textile-composites-for-seat-upholstery

https://www.compositesworld.com/articles/camismas-car-seat-back-hybrid-composite-for-high-volume

Material Concepting

Concepts for what materials to use

Should be split into separate components for ease: Brace (shell), foams, and seat cover (cloths).

Brace:

Should be cf (the concepts of aluminum and other composite metals was discussed and the skills set needed to work with these materials cannot be done in house).

Fiberglass/CF shell doesn’t improve the strength of the seat and therefore, we should if possible, use an entirely CF shell.

Foam:

Seat covering/cloth:

Mesh fabric (backpacks),

Manufacturing Concepting

Concepts for what manufacturing processes to use

Construction of the shell:

• plug

• cut out

• mold

Construction of the foams:

How to work with cloth:

Assembly Concepting

Concepts for how various materials and parts will assemble together

Foam to seat: DP-420

Cloth to foam: sewing and Double-sided tape/3M 78

Cloth to seat: DP-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?

Test the glue in hot and humid conditions

Test with human interaction (if moving around in the seat will cause the foam to tear or to rip the Velcro or hooks, etc)

Test if materials a comfortable (get a sample and put it on your work chair and see if you can sit on it all day)

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

Seats Manufacturing

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

Put into machine