Interiors S2021 Planning

This document outlines the tasks for the Interiors team for the Spring 2021 term.

Term Goals

Project	Goal	OG Date	Date (March)	Priority

Project	Goal	OG Date	Date (March)	Priority
Catamaran Cover	Complete manufacturing	3 months End of May	3 months End of Sep	High
Seats	Complete manufacturing (plan https://docs.google.com/document/d/1t6-ZhpMnQ-8Mp0LCcsmOvhaA2A8u8Zm8mg8Jn0yAIVg/edit# ) testing to confirm design start seat pan manufacturing weld brackets to the chassis	2 months End of April	2 Months F21	High
Doors	Complete FULL manufacturing plan (EOT W21) Hinges and Latch need access to A-Plane Latch & Hinges components (2w) Molds & Composites Need manufacturing plan Manufacturing time ** Any Structures changes to hinges need to be communicated	2 months End of February	Manufacturing Time: 2 months Commitment for Manufacturing Completion: Mid-F21	High
Trim	Complete detailed design Started manufacturing plan Currently figuring out headliner	4 months Fall Term Trim Integration: 2 months		Medium
Dashboard	Complete detailed design Started manufacturing plan	4 months Detailed design & Completed Manufacturing Plan: Mid-S21 Manufacturing: 3 months Integration: 1-2 months		High

Manufacturing Projects

Will recommend that we email the Scrutineers that review the VDRs to get feedback on our seats and steering wheel, both of which we are designing from scratch. VDR is in progress for seats (~85% completed).

Project	Task	Time Allocation	Status

Project	Task	Time Allocation	Status
Catamaran Cover + Seats	Obtain all materials required for manufacturing the catamaran cover (MDF, layup consumables) Finish assembly plan	BOT	In PRogress All MDF for catamaran cover by mid-march, mdf for seats and doors by EOT
Catamaran Cover	Manufacture Molds Cut and glue MDF Machine molds Sand and prime	2 weeks	Not Started
	Manufacture Major Battery Box Panels (bottom + side walls + lid) Prep work Make extra for test specimens	3 weeks	Not Started
	Manufacture Internal Parts • 3D printing • Cutting and thermoforming polycarbonate	1 week	in progress
	Material Testing Deflection test Heat test Adhesive test	1 week	Not Started
	Dry Run Assembly with Electronics • Install electronics and battery modules • Mark part locations • Test fit catamaran cover into car → Will gate electrical	1 week	Not Started will require coordination of finished chassis, bottom panel, battery modules
	Final Assembly • Epoxy internal components • Install electricals • Permanent mounting of catamaran cover to chassis	2 weeks	Not Started
	External Finish • Add fabrics and other cosmetic trim to battery box Nice to Have	TBD	Not Started
Seats	Seats Mock-up (optional) • Fabricate and install flat panels in wood to verify seating position, harness pass-thru, visibility, steering wheel and pedal position • May need to mock-up seatback using flat sheets	1 week	DONE
	Manufacture Seats Flat Panels using the Glass panel Fabricate all seat pan flat panels in carbon fibre (either in 1 go or 2 depending on the size of vacuum bag) Bond flat panels to bottom panel/structural elements	2 weeks	Not Started
	Manufacture seat supports depending on method chosen: 2 built in filets (require small amount of mdf and require producing each seat support separately which is time consuming considering there are 8 of them) 1 built in filet (require producing each seat support separately which is time consuming considering there are 8 of them) 0 built in filets (will be weaker around 1.5-3 times based on research but can manufacture flat pieces 4 supports at a time meaning there will only be 2 rounds of infusion)	2 filets 3 weeks 1 filet 2-3 weeks 0 filets 1 week	Not Started
	Ballast using using the Glass panel after install of seat pan the measurements and checking to make sure the ballast will hold enough weight/there will enough room begin manufacturing flat panels (glass sheet) install with hinges, lock, and lid	2 weeks	Not Started
	Brackets and fastener installation order brackets (if VDR approved) order bigheads order fuji/flex locks drill appropriate holes and weld brackets onto chassis	3 weeks	Not Started Further purchases are required (brackets approved by EngSoc) fasteners TBD
	Manufacture Seatbacks • Fabricate tooling for non-flat panels (mdf) • Fabricate non-flat seatback panels • Install seatbacks into car	2 weeks + 1 week = 3 weeks	Not Started
	Finishing Touches • Fabricate foam padding and cushions and install • Fabricate and install remaining fabric coverings • Install harnesses	TBD	Not Started These can be done over long term Further purchases are required: fabric

Integration with Subteams/Dependencies

Catamaran depends on:
- Aero-chassis BP integration
- Battery box modules ready
- Dynamics assembly
Seats depends on:
- Chassis integration
- Side panel integration (for rear seats install)
- Floor panels SHOULD NOT need to be added into the vehicle (so that brackets can be welded)
- Welding items for chassis
- B,C-bulkheads Integrated
Dashboard depends on:
- Dynamics
- Aero-Chassis Integration (A-bulkhead, A-Plane)
- Interior doors
- Electrical & Battery Box need to be integrated so we can route wires
  - Depends on Displays & cameras to be ready

Contingency Planning

If lockdown happens, manufacturing will be impacted as long as lockdown remains

Design Projects (Trim + Dashboard)

Task	Time Allocation	Status

Task	Time Allocation	Status
Finalize Research + Concepting	2 weeks	In PRogress
CAD design	4 weeks	In PRogress
Materials Selection	2 weeks	In PRogress
Supplier Interfacing Assembly Plan	TBD	Not Started

Core Team

Name (Term)	Responsibilities	On-site Capacity

Name (Term)	Responsibilities	On-site Capacity
Renzo (Co-op)	• Leading manufacturing of catamaran cover • Form factoring of dashboard	On-site
Sheila (School)	• Leading manufacturing of seats	On-site
Ali (School)	•Design and integration of Dash	On-site
Cordelia (School)	• PM for dashboard • PM for seats	On-site
Asher (Co-op)	• Leading manufacturing of seats	Remote
Kimia (School)	• Design of ballast	On-site
Lovisa (Co-op)	• PM of trim	Remote
Jens (School)	Trim	On-site
Joy ()	Dashboard	On-site

Onboarding Project

Onboarding Project Instructions