After the Odyssey 1 launch, a new nosecone was necessary for the Far Mars Competition in Spring of 2018. The details and imagery for recreating the nosecone are presented below.
This time, production methods were shifted to allow mass rapid production; instead of using a 3D Printed Male Mold, a plug would be used to create a female mold from which multiple nosecones could be created.
To create the plug, the previous SolidWorks CAD was modified by myself and Bhav Patel to accommodate PVA Plastic and thicker walls. Due to the relatively small 3D Printers (Lulzbot Taz 5), the plug was printed in multiple parts.
Next, to create a surface smooth enough to enable creation of a female mold, a combination of primer and bondo was heavily applied. After wet sanding with 120, 220, and 600 grit sandpaper, the surface of the plug was exceedingly smooth with a pretty color scheme.
Next, multiple layers of Fibreglast part-all paste were applied; this petroleum based wax facilitates the smoothing on the surface and easess separation of the cured fiberglass.
With this completed plug, a wooden form with the profile of the nosecone was cut. This is shown below.
After using basic modelling clay to fill any gaps between the plug and the wooden profile, three layers of PVA Release Agent were applied; these pictures depict the agent as it dries, leaving a shiny, glossy surface.
Once the layers of the release agent dried, the female mold layup began. 18 +/- 2 Layers of fiberglass were used.
After curing, the excess fiberglass around the border was removed with dremel; a fresh layer of PVA Release Agent and Part-all wax was also applied. This will provide the surface upon which the second half of the female mold cures.
Pictured below is the removal of the female mold after layup, after one failed initial attempt. The initial attempt would ultimately be trimmed into a boattail.
Once smoothed, the nosecone was then placed in the oven for 18 hours, during which the hardened high temp epoxy was thoroughly cured. This resulted in a distinct amber coloring, as shown.
The following pictures were taken during launch, after painting and integration.
Unfortunately, a design flaw in the internal structure left a specific weakness to tosrion; in addition, the Cg may have been slightly off from the longitudinal axis, leading to instabilities which ultimately caused in-flight explosion. The video (courtesy of a bystander) is shown below.
In spite of the unsuccessful recovery, many lessons were learned and the drive to improve has never been stronger. UCLA Rocket Project as a whole will strive to achieve new heights.
This concludes Odyssey 2, and my time as Nosecone Lead for the UCLA Rocket Project. On Odyssey 3, I will be taking on the role of Recovery Lead.
This time, production methods were shifted to allow mass rapid production; instead of using a 3D Printed Male Mold, a plug would be used to create a female mold from which multiple nosecones could be created.
To create the plug, the previous SolidWorks CAD was modified by myself and Bhav Patel to accommodate PVA Plastic and thicker walls. Due to the relatively small 3D Printers (Lulzbot Taz 5), the plug was printed in multiple parts.
Next, to create a surface smooth enough to enable creation of a female mold, a combination of primer and bondo was heavily applied. After wet sanding with 120, 220, and 600 grit sandpaper, the surface of the plug was exceedingly smooth with a pretty color scheme.
Next, multiple layers of Fibreglast part-all paste were applied; this petroleum based wax facilitates the smoothing on the surface and easess separation of the cured fiberglass.
With this completed plug, a wooden form with the profile of the nosecone was cut. This is shown below.
After using basic modelling clay to fill any gaps between the plug and the wooden profile, three layers of PVA Release Agent were applied; these pictures depict the agent as it dries, leaving a shiny, glossy surface.
Once the layers of the release agent dried, the female mold layup began. 18 +/- 2 Layers of fiberglass were used.
After curing, the excess fiberglass around the border was removed with dremel; a fresh layer of PVA Release Agent and Part-all wax was also applied. This will provide the surface upon which the second half of the female mold cures.
Pictured below is the removal of the female mold after layup, after one failed initial attempt. The initial attempt would ultimately be trimmed into a boattail.
Once smoothed, the nosecone was then placed in the oven for 18 hours, during which the hardened high temp epoxy was thoroughly cured. This resulted in a distinct amber coloring, as shown.
The following pictures were taken during launch, after painting and integration.
In spite of the unsuccessful recovery, many lessons were learned and the drive to improve has never been stronger. UCLA Rocket Project as a whole will strive to achieve new heights.
This concludes Odyssey 2, and my time as Nosecone Lead for the UCLA Rocket Project. On Odyssey 3, I will be taking on the role of Recovery Lead.
Comments
Post a Comment