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First and foremost, I want to give credit to Hubert - ETS alumni and previous composites lead on their team. This was a concept that they used to create their roof mold and they had great success with it.

Concept

This concept resembled shipbuilding more than mold manufacturing. The basic premise is we set up ribs, and then put a sheet of aluminum on top, which acts as the mold surface. Below are some pictures to give you an idea.

Ribs

View from underneath

Final mold

The sheet of aluminum on top will bend under its own weight and follow the contour of the ribs. After that, the top sheet is welded or adhered to the ribs. For this style of mold, the ribs geometry and curvature dictate the shape of the panel.

A limiting factor is that the panel can only have a bend in one axis. Panels with complex surfaces such as side panels, cannot be manufactured in this way as they would need to be stamped and cannot rely on gravity to form the sheet.

Brief task outline and goals

Team member

Aidan Lehal

Abdelrahman Hassouneh (Unlicensed)

Mohamed Goha

Salman Rasheed

Min Qian Lu (Deactivated)

Task as of March 22 '21

Material, solar array and bonding solutions

Validating that the roof can be done in this manner

Creating process to create CAD

SI/speccing. Will work closely with Aiden. Currently finding aluminum

Lead

  • Material, solar array, and bonding solutions

    • Find material that is suitable both for ribs and top sheet

      • ribs must be held to a high degree of dimensional tolerance

      • 3/4” MDF had a history of cracking at ETS. We can either increase number of ribs, change the slot geometry on the ribs, or somehow decrease load on each rib

      • also, consider build surface. At ETS, they used a jig of sorts

    • Solar array

      • want to include solar cut-outs on our mold

      • probably brainstorm ideas and run them by Brian from E5

    • Bonding

      • bond ribs and top sheet

      • would be nice to avoid welding but need a solution that is still sturdy

  • Validating that roof can be done in this manner

    • validating that the panel only contains one curve. Otherwise, geometry cannot be achieved.

  • Creating a process to create mold CAD

    • precursor to the actual CAD

    • for now, focusing on creating ribs that accurately allow us to “form” the sheet metal such that the top surface of the sheet is identical to the desired surface

  • SI/Speccing

    • work on finding aluminum supplier from interiors

    • also finding materials that are up to spec (strength, temperature, weight etc.), work with Aidan on this one

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