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Manufacturing detailed steps

Seats Cushions:

Materials:

·        Neoprene 1/2 in thickness foam

·        Polyethylene open cell high density 1 in foam

·        Meidong Nano Tape Double Sided Super High Viscosity Tape Roll or Polystyrene Foam Insulation 78 Spray Adhesive

·        Scissors

·        2 part epoxy (DP-420)

·        3M SJ3550 Dual Lock Recloseable Fastener

Manufacturing:

  1. Using the 2 part epoxy (DP-420) (making sure to pull the neoprene over the edges of the seat back) adhere to seat back and seat pan

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

  3. Place the open cell on the areas that need to be padded based on the mockup (again use the tape/cement to secure the soft open cell to the closed cell)

  4. The contouring of the foam will need a jig

Seat Pan:

Materials:

·        Carbon fiber flat panel from the flat panel (2 layer carbon fiber each side)

·        DP-420 Black

·        Neoprene foam

·        Polyethylene foam

·        ¾ inch divinycell foam

Manufacturing:

  1. Infusion process using the flat panel (glass sheet will work)

  2. Cut from the panel into the shape needed with cnc

  3. Cut foam to fit inside the seatback (please see assembly doc)

  4. Adhere foam together with the tape/spray (will need to be clamped down)

  5. 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)

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

  7. Make sure the edges are covered (either with tape or foam so there is no carbon fiber to person contact)

Seat back:

Materials:

·        Carbon fiber 6.2oz x 50” Twill Carbon

·        MDF mold from wood

·        Cnc routed for the cuts (cnc for the mold and the cutting of the hole for the inserts)

·        Peel/wax

·        Divinycell foam core (1/4 in)

·        Tacky tape

·        Vacuum bag

·        Resin

·        Neoprene foam

·        Polyethylene foam

·        90 degree brackets

·        Rivets or Fujilok

Manufacturing:

  1. Take CAD mold and CNC them

  2. Line mold with wax (anti-peeler)

  3. Take the carbon fiber (2 layers) take the divinycell foam and poke holes about an inch apart then place another 2 layers of carbon fiber on top and cut a section of Kevlar to place in the shoulder region

  4. Set up vacuum and resin infuse

  5. Remove from the mold

  6. Cut foam to fit inside the seatback (please see assembly doc)

  7. Adhere foam together with the tape/spray (will need to be clamped down)

  8. 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)

  9. Adhere extra support to the foam with the tape/spray (side cushioning, bolsters, lumbar, and headrest)

10.   The seatback will be attached to the chassis using 90 degree brackets and rivets (drill through the C bulkhead and attach to the chassis)

Seat Supports:

Materials:

·        Carbon fiber flat panel

·        DP-420

·        Foam mold

·        Divinycell foam core (3/4 inch)

·        90 degree brackets

·        Highlock or fujilock or rivets

·        Filet support marterial (to support the 90 degree panel)

·        Rivets and washers

Manufacturing:

  1. Use the foam mold with 90 degree edge to manufacture the panel

  2. Cut holes for chassis (using a machine)

  3. Adhere all flat panels to each other using DP-420

  4. Attach to the bottom panel using DP-420

  5. Attach rivets to the seat pan and the edge of the seat supports in a single lap joint

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

·        Locks

·        Highlock or fujilock or rivets

·        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 attach to chassis

  5. Adhere lock onto the ballast lid

Inserts:

·        3D printer

·        PC-ABS plastic with solid fill and standard should be ok

Manufacturing:

  1. Take mold from CAD

  2. Put into machine

 

 

 

 

 

 

 

 

 

 

 

 

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