Objectives:
- Practice composites manufacturing methods
- Derive mass/length of fuselage from physical model
Procedures:
Materials and Equipment:
| Materials |
QTY |
| ASA Aero Fuselage Shell |
1 |
| 2.74oz/yd^2 Fiberglass |
A/N |
| Aero-Poxy Epoxy |
A/N |
| Glass Micro balloons |
A/N |
| CAB-O-SIL |
A/N |
| Lightweight Spackling |
A/N |
| Bondo Red filler |
A/N |
|
|
| Consumables/Equipment: |
QTY |
| Nitrile Gloves |
A/N |
| Mixing Cups |
A/N |
| Mixing Sticks |
A/N |
| Paper Towels |
A/N |
| Peel Ply |
A/N |
| Saran Wrap |
A/N |
| Paint Brush |
A/N |
| Epoxy/Paint Roller |
A/N |
| Sandpaper / Sanding block (120-400 grit) |
A/N |
| Isopropyl alcohol |
A/N |
| Plastic Spreader |
A/N |
| Composite Shears |
1 |
| Sharpie Marker |
A/N |
| Scale |
1 |
| Lab Coat |
1 |
| Safety Goggles |
1 |
| Respirator (P900 filters) |
1 |
PPE:
All subsequent steps require use of the following PPE:
- Nitrile Gloves
- Respirator, P900 filters
- Lab Coat
- Safety Goggles
Surface Preparation:
- [ ] 1. Roughly abrade both inner and outer surfaces of the 3D printed shell using 120 grit sandpaper.
- [ ] 2.Continue sanding, working up from 120 to 400 grit, taking care not to excessively remove material. Once the surface is smooth and free of large bumps (layer line ridges are acceptable), continue to the next step.
- [ ] 3.Fill in the rough ridges left from the 3D printing process with lightweight spackling, using a plastic spreader to ensure a thin layer of filler is applied.
- [ ] 4.Once the filler has cured, repeat steps 1-2 until a smooth surface is achieved again.
- [ ] 5.Fill in any low spots and any left over surface imperfections with a thin layer of Bondo Red, again using a plastic spreader to smooth out the filler.
- [ ] 6.Once the Bondo has cured, repeat steps 1-2 until a smooth surface is achieved.