Body_Material

Subteam: AerodynamicsSubsystem: Body Work and NoseAssembly: BodyCars: CR21

Purpose

CR21 line item for the raw composite material used in the body panels.

Function

Now tracked through the laminate weight calculator and the schedule for each panel.

Design Process

No part-specific design process is documented. The Body Work and Nose subsystem design process applies: 1. Take the outer surface from the aerodynamics CFD geometry so the panel is the same surface that was simulated. 2. Choose a laminate schedule using the team's laminate weight calculator, trading ply count against stiffness and surface finish. 3. Mold: tooling board milled on the 5-axis gantry for large surfaces, 3D printed molds for small parts. Automotive clearcoat over the print cut roughly 22 hours of sanding and made the molds reusable. 4. Layup and cure, then post-process, fill the leading edges with polyester filler and satin clearcoat for UV protection. 5. Test fit on the frame, then trim and drill mounting hardware to jigs.

Reoccuring issues

None recorded. This part has no entry in Knowledge_Transfer/Issue Logging/Fault Vault.xlsx, in either Issue Log.xlsx, in CR22/Issue Tracking/Shakedown 7-15-23.xlsx, or in any design review issue list found in CrimsonStorage or Box.

Still to document

Nothing in CrimsonStorage covers these yet.

Design Constraints — What held back the design whether it be location, time, materials etc
Analysis — How you get quantitative, predictive information on the part
Manufacturing Process — How it is assembled in detail from start to finish
Full Material List — Everything used to build this part (Best if actual numbers are used to show how it evolves year to year)
Improvements — Improvements for this generation
Properties — Size, weight, mass, charge, thermal properties, anything else relevant