Objectives:

  1. Test molded leading edge (LE)
  2. Develop final wing configuration
    1. Root: 0 - 575
    2. Middle_1: 575 - 1150
    3. Middle_2: 1150 - 1720
    4. Tip: 1720 - 1800
  3. 3D Print:
    1. Root rib + shear web
    2. Root - M_1 joiner + rib + and root shear web
    3. M_1 - M_2 joiner + rib
    4. Tip rib and wingtip mount
  4. M_1 - M_2 joiner to be forged CF, out of cf tow
  5. Streamline manufacturing process
  6. Develop procedure for wing construction

Changes from Test 1:

  1. Updated hot wire templates with 1mm kerf
    1. Laser Cutter Settings (HD 1/4 Ply):
      1. Power 70
      2. Speed 0.4
      3. PPI/Hz 10000
  2. Wing section 2 → 3
    1. WAS: 80 - 1150, 1150 - 1720
    2. IS: 0 - 575, 575-1150, 1150 - 1720
  3. Add mid wing break @ 575mm
    1. Additional 3D printed joiner/rib elements
    2. Forged CF joiner bar
    3. Root side joiner to also incorporates root shear web
  4. Add 3DP root rib / shear web
    1. 1x wall, 15% rectilinear infill
  5. Vacuum press. WAS: 6inhg, IS: 7inhg
  6. CONSIDER: Manufacturing spar separately:
    1. First cut foam core
    2. Then cut away spar area (mark on foam beds where cut is)
    3. Lay up spar/shear web first, mylar and vacuum bag
    4. Sand and prep spar for bonding
    5. Use super 77 to bond spar back to foam TE and 3DP LE

Test Article:

Screenshot 2024-08-23 at 1.48.27 PM.png

Configuration Overview: