1. Prepare Overwrap Materials
High temp vacuum bag | 20" x 22" |
Low temp vacuum bag | 20" x 22" |
Breather cloth | 14" x 20" |
High temp peel ply | 14" x 20" |
High temp release film | 14" x 20" |
Butcher paper | 14" x 30" |
Carbon fiber | 14" x 30" |
2. Layup Phenolic Tube
Systems 3000 epoxy applied to carbon fiber (3)
2-3 team members
3-4 hours
Consistent set-up & execution needed
3. Phenolic Tube Cure
Cure at room temperature in low-temp vacuum bag for 24-36 hours
Oven cure for an additional 12 hours in high-temp vacuum bag
4. Attach Fins to Fin Can
5. Apply Root Fillet to Fins
¾” radius Systems 3000 epoxy with 9% cabosil
Each pair of fillets require 18-24 hours to cure
Each pair of trailing edges require 18-24 hours to cure
6. Prepare Tip-to-Tip Materials
High temp vacuum bag (4) | 20" x 22" |
Low temp vacuum bag (4) | 20" x 22" |
Breather cloth (4) | 14" x 20" |
High temp peel ply (4) | 14" x 20" |
High temp release film (4) | 14" x 20" |
Butcher paper (32) | 12" x 18" |
Carbon fiber (32) | 12" x 18" 12" x 22" 14" x 22" |
7. Layup Fin Can Tip-to-Tip
Systems 3000 epoxy applied to carbon fiber (4x8)
4-5 team members
3-4 hours
Consistent set-up & execution needed
8. Mitigating Wrinkles
Do not exceed pot life of the epoxy → can’t be pulled out later
Ensure that the carbon fiber doesn’t bunch up / shift during layup
Use extra breather to prevent the vacuum connector from denting carbon fiber
Double check vacuum is connected correctly
Minimize wrinkles in all layers: release film, peel ply, etc.
Don’t use the foam technique near the fillets unless we know it’s gonna work
Make sure there is not a lot of excess carbon fiber near the fillet (needs to fit the profile pretty closely)
Cure at room temperature in low-temp vacuum bag for 24-36 hours
Oven cure for an additional 12 hours in high-temp vacuum bag
Week 1 | Assemble new manufacturing jigs. Establish fin can testing jigs. Prepare overwrap kit for phenolic tube #2. |
Week 2 | Cut G10 fins on waterjet. Apply root bond and begin fillets for fin can #1. Prepare tip-to-tip kit for fin can #1. |
Week 3 | Overwrap and cure phenolic tube #2. Finish applying fillets to fin can #1. Prepare tip-to-tip kit for fin can #2. |
Week 4 | Apply tip-to-tip and cure fin can #1. Apply root bond and begin fillets for fin can #2. Prepare overwrap kit for phenolic tube #3. |
Week 5 | Overwrap and cure phenolic tube #3. Finish applying fillets to fin can #2. Prepare tip-to-tip kit for fin can #3. |
Week 6 | Apply tip-to-tip and cure fin can #2. Apply root bond and begin fillets for fin can #3. Test fin can #1. |
Week 7 | Finish applying fillets to fin can #3. Test fin can #2. |
Week 8 | Apply tip-to-tip and cure fin can #3. Test fin can #3. |
