Doors Design Review - April 15, 2021

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The same slide deck is being used for check-in updates. The specific slides from the April 15 design review are at the tail end of the deck.

Form Factor

Hinge

• Mounting hinge to chasses with M6 bolts

• Will need to cut sections out of the side panel, which will be covered in a thin neoprene

Latch System

• Two different handles for the interior and exterior

  • Exterior handle → pushrod system, to 3D print

    • Pushrod 'z' pieces is made up of 2 pieces connected together → to try and close the gap into more of a triangle

    • To test how much force the handle can withstand

• Will be 3D printing parts for quick prototyping

• Bear claw latch snaps onto the striker on impact

  • Latch striker is a threaded rod secured to the chassis with 2 nuts

• Latch mounts to be 3D printed

• Concerns and low confidence in the structural integrity of the parts

  • multiple parts, many being 3D printed → concerns around fatigue, especially sicne the doors will be swinging open and closed very often

  • Many of these could be laser cut sheet metal instead

Simulations

• Initial sim results might be a factor off due to how course the mesh used

Next steps

• Refine constraints

Molds

• No 90 degree bends seen - all are fitted

• Is it possible to merge the latch cover and handle cover?

  • Was told to split them up by Adrian

  • Shouldn’t be a problem if they’re split up since the parts are so small

  • Latch cover molds might want to be removed versus the handle covers

  • A problem that happened with aero - side panels are separate from the doors which left them to manufacture an extra 4 molds when they could have just done one mold and cut out the shapes of the panels afterward

Interior Door Panels

• Different for the front and back

• 3 different fiberglass parts and a wooden armrest make up the interior panels

• cantilevers were recommended by the machinist for the armrest → possibly some concerns

Timelines

• Will, unfortunately, be dictated by covid

• Can install latches while manufacturing molds (can be done in parallel)

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Potential Future Purchases

• Neoprene

• Foam cutter?

• Mcmaster carr order for bolts, buts and washers (if we cannot salvage any from the bay)

• Adhesives

  • Need. 3main ones to interface between: metal and composite, 3D printer filament and composite, wood and composite

• 3D printing filament → PETG or polycarbonate?

• Tape