Hermes 2 Nose Cone Design & Manufacturing

Above: Hermes 1 nose cone mold (4 layers of 1" thick MDF, sanded and finished with gel coat), manufactured by Raul Largaespada.

Hypersonic optimum

5.5:1 fineness ratio

NC tip material: __________

What size bolt?

Phenolic washer

Overview of Nose Cone Design

Shape, materials, length, fineness ratio, tip dimensions and material, washer, bolt, method for attaching thermocouples, etc.

*remember that you need TWO halves of the mold.

Talk about mold materials used (MDF, gel coat), why fiberglass used

Required Materials:

Create design of mold in Solidworks (using "Solidworks mold tools" --> helpful tutorial: https://youtu.be/yqROZFStz6c)
Calculate how much MDF needs to be used (based on thickness, dimensions of nose cone). Make sure to account for extra area for pry slits and alignment pins.
We want the mold to be very regular (90 degree angles) so that alignment when routing will be easier. Cut MDF using a table saw or a bandsaw (where can we find table saw?)
Glue layers together (using what?)
Alignment pins and pry slits? (what are pry slits? what order should this be done in? how many pins?
Download Mastercam: http://ist.mit.edu/mastercam
Plot a path to cut the mold using Mastercam
Go to Hobby Shop to get help from peeps
Take notes of helpful tips and add to this Wiki article
When routing:
1. Make sure the router is routing the correct shape- pause if necessary.
2. Lots of sawdust will be generated, so follow the router tip with a vacuum to get most of it.

Required Materials:

Sand the mold, starting with 400 grit and working up to 1000 and 2000. This will take a long time!
Apply 5 layers of gel coat (respirator required)

Required Materials:

Required Materials: