{"id":569,"date":"2022-01-19T19:12:12","date_gmt":"2022-01-19T19:12:12","guid":{"rendered":"https:\/\/labs.ri.cmu.edu\/moonranger\/?p=569"},"modified":"2022-01-19T19:14:56","modified_gmt":"2022-01-19T19:14:56","slug":"chassis-shell-fabrication","status":"publish","type":"post","link":"https:\/\/labs.ri.cmu.edu\/moonranger\/chassis-shell-fabrication\/","title":{"rendered":"Chassis Shell Fabrication"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"569\" class=\"elementor elementor-569\" data-elementor-post-type=\"post\">\n\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-1e68a56a elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"1e68a56a\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-352d5321\" data-id=\"352d5321\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-5b213bb elementor-widget elementor-widget-text-editor\" data-id=\"5b213bb\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400\">MoonRanger\u2019s carbon fiber composite chassis shell was a triumph of design, process and master craft. Although metal design and machining is much more straightforward, only a composite solution was sufficiently lightweight. A campaign of design, facility development, mold-making, process development, layup, curing and machining created this elegant structural element. The 18\u201d x 17\u201d x 4\u201d stiff, strong flight shell weighs only 820 grams.\u00a0<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-0fdfc62 elementor-widget elementor-widget-heading\" data-id=\"0fdfc62\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">The Layup Stage<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-eaadd54 elementor-arrows-position-inside elementor-pagination-position-outside elementor-widget elementor-widget-image-carousel\" data-id=\"eaadd54\" data-element_type=\"widget\" data-settings=\"{&quot;slides_to_show&quot;:&quot;1&quot;,&quot;navigation&quot;:&quot;both&quot;,&quot;autoplay&quot;:&quot;yes&quot;,&quot;pause_on_hover&quot;:&quot;yes&quot;,&quot;pause_on_interaction&quot;:&quot;yes&quot;,&quot;autoplay_speed&quot;:5000,&quot;infinite&quot;:&quot;yes&quot;,&quot;effect&quot;:&quot;slide&quot;,&quot;speed&quot;:500}\" data-widget_type=\"image-carousel.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-image-carousel-wrapper swiper\" role=\"region\" aria-roledescription=\"carousel\" aria-label=\"Image Carousel\" dir=\"ltr\">\n\t\t\t<div class=\"elementor-image-carousel swiper-wrapper\" aria-live=\"off\">\n\t\t\t\t\t\t\t\t<div class=\"swiper-slide\" role=\"group\" aria-roledescription=\"slide\" aria-label=\"1 of 5\"><figure class=\"swiper-slide-inner\"><img decoding=\"async\" class=\"swiper-slide-image\" src=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Layers.png\" alt=\"The shell is laid up in six layers using a total of 46 pieces of carbon fiber prepreg. Each successive layer bridges over the seams of interlocking elements on adjacent plies, ensuring there are no weak points in the shell.\" \/><figcaption class=\"elementor-image-carousel-caption\">The shell is laid up in six layers using a total of 46 pieces of carbon fiber prepreg. Each successive layer bridges over the seams of interlocking elements on adjacent plies, ensuring there are no weak points in the shell.<\/figcaption><\/figure><\/div><div class=\"swiper-slide\" role=\"group\" aria-roledescription=\"slide\" aria-label=\"2 of 5\"><figure class=\"swiper-slide-inner\"><img decoding=\"async\" class=\"swiper-slide-image\" src=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Symmetry-768x580.png\" alt=\"Each piece is applied with meticulous care, ensuring that placement is symmetric. Rollers are used to force out any bubbles and press each layer against the mold.\" \/><figcaption class=\"elementor-image-carousel-caption\">Each piece is applied with meticulous care, ensuring that placement is symmetric. Rollers are used to force out any bubbles and press each layer against the mold.<\/figcaption><\/figure><\/div><div class=\"swiper-slide\" role=\"group\" aria-roledescription=\"slide\" aria-label=\"3 of 5\"><figure class=\"swiper-slide-inner\"><img decoding=\"async\" class=\"swiper-slide-image\" src=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Interlocking-Pieces.png\" alt=\"Interlocking pieces are carefully placed such that there is no gap between edges.\" \/><figcaption class=\"elementor-image-carousel-caption\">Interlocking pieces are carefully placed such that there is no gap between edges.<\/figcaption><\/figure><\/div><div class=\"swiper-slide\" role=\"group\" aria-roledescription=\"slide\" aria-label=\"4 of 5\"><figure class=\"swiper-slide-inner\"><img decoding=\"async\" class=\"swiper-slide-image\" src=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Ply-Orientation.Combined-768x359.jpg\" alt=\"Ply-orientation is a significant consideration in the layering to maximize homogeneity and strength of the layup. The completed shell is quasi-isotropic.\" \/><figcaption class=\"elementor-image-carousel-caption\">Ply-orientation is a significant consideration in the layering to maximize homogeneity and strength of the layup. The completed shell is quasi-isotropic.<\/figcaption><\/figure><\/div><div class=\"swiper-slide\" role=\"group\" aria-roledescription=\"slide\" aria-label=\"5 of 5\"><figure class=\"swiper-slide-inner\"><img decoding=\"async\" class=\"swiper-slide-image\" src=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Rolling-768x523.png\" alt=\"Once the layers are complete, a final rolling ensures all pieces are flat against the mold. This completes the layup stage.\" \/><figcaption class=\"elementor-image-carousel-caption\">Once the layers are complete, a final rolling ensures all pieces are flat against the mold. This completes the layup stage.<\/figcaption><\/figure><\/div>\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t\t\t<div class=\"elementor-swiper-button elementor-swiper-button-prev\" role=\"button\" tabindex=\"0\">\n\t\t\t\t\t\t<i aria-hidden=\"true\" class=\"eicon-chevron-left\"><\/i>\t\t\t\t\t<\/div>\n\t\t\t\t\t<div class=\"elementor-swiper-button elementor-swiper-button-next\" role=\"button\" tabindex=\"0\">\n\t\t\t\t\t\t<i aria-hidden=\"true\" class=\"eicon-chevron-right\"><\/i>\t\t\t\t\t<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t<div class=\"swiper-pagination\"><\/div>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-291446e0 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"291446e0\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-5e539e03\" data-id=\"5e539e03\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-6e5dcc4 elementor-widget elementor-widget-heading\" data-id=\"6e5dcc4\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">A Vacuum Environment<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-330c51b2 elementor-invisible elementor-widget elementor-widget-image-gallery\" data-id=\"330c51b2\" data-element_type=\"widget\" data-settings=\"{&quot;_animation&quot;:&quot;fadeIn&quot;}\" data-widget_type=\"image-gallery.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-image-gallery\">\n\t\t\t<div id='gallery-1' class='gallery galleryid-569 gallery-columns-3 gallery-size-medium'><figure class='gallery-item'>\n\t\t\t<div class='gallery-icon landscape'>\n\t\t\t\t<a data-elementor-open-lightbox=\"no\" href='https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Layers-Diagram.png'><img fetchpriority=\"high\" decoding=\"async\" width=\"300\" height=\"182\" src=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Layers-Diagram-300x182.png\" class=\"attachment-medium size-medium\" alt=\"\" srcset=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Layers-Diagram-300x182.png 300w, https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Layers-Diagram-768x465.png 768w, https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Layers-Diagram.png 824w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/a>\n\t\t\t<\/div><\/figure><figure class='gallery-item'>\n\t\t\t<div class='gallery-icon landscape'>\n\t\t\t\t<a data-elementor-open-lightbox=\"no\" href='https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Vacuum-Bag.png'><img decoding=\"async\" width=\"300\" height=\"256\" src=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Vacuum-Bag-300x256.png\" class=\"attachment-medium size-medium\" alt=\"\" srcset=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Vacuum-Bag-300x256.png 300w, https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Vacuum-Bag.png 681w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/a>\n\t\t\t<\/div><\/figure><figure class='gallery-item'>\n\t\t\t<div class='gallery-icon landscape'>\n\t\t\t\t<a data-elementor-open-lightbox=\"no\" href='https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Vacuum-Oven.png'><img decoding=\"async\" width=\"300\" height=\"201\" src=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Vacuum-Oven-300x201.png\" class=\"attachment-medium size-medium\" alt=\"\" srcset=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Vacuum-Oven-300x201.png 300w, https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Vacuum-Oven-768x515.png 768w, https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Vacuum-Oven.png 901w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/a>\n\t\t\t<\/div><\/figure>\n\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-84c5a56 elementor-widget elementor-widget-text-editor\" data-id=\"84c5a56\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400\">The layup is cured under vacuum. The technique utilizes atmospheric pressure to evenly press the composite layers against the mold. Several layers of material are introduced between the composite laminate and the vacuum bag. Breather fabric facilitates air evacuation while pulling vacuum, caul plates are used to ensure flat faces of the shell are clamped evenly, and release film inhibits bonding between the laminate and the aforementioned layers. <\/span><span style=\"font-weight: 400\">The mold, shell, and aiding layers are placed inside a vacuum bag. Note that the layup and curing occur in a temperature and humidity controlled clean room environment. <\/span><span style=\"font-weight: 400\">Under vacuum, all layers are squeezed against the mold. The unit (still under vacuum) is partially cured in an oven, followed by complete cure in an autoclave. The autoclave is pressurized to several atmospheres, offering a multi-fold increase in clamping force beyond what is possible by vacuum alone.&nbsp;&nbsp;<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8d68d8a elementor-widget elementor-widget-image-gallery\" data-id=\"8d68d8a\" data-element_type=\"widget\" data-widget_type=\"image-gallery.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-image-gallery\">\n\t\t\t<div id='gallery-2' class='gallery galleryid-569 gallery-columns-1 gallery-size-medium_large'><figure class='gallery-item'>\n\t\t\t<div class='gallery-icon landscape'>\n\t\t\t\t<a data-elementor-open-lightbox=\"yes\" data-elementor-lightbox-slideshow=\"8d68d8a\" data-elementor-lightbox-title=\"Chassis Shell Pre Cutouts.Combined\" data-e-action-hash=\"#elementor-action%3Aaction%3Dlightbox%26settings%3DeyJpZCI6NTc2LCJ1cmwiOiJodHRwczpcL1wvbGFicy5yaS5jbXUuZWR1XC9tb29ucmFuZ2VyXC93cC1jb250ZW50XC91cGxvYWRzXC9zaXRlc1wvMjRcLzIwMjJcLzAxXC9DaGFzc2lzLVNoZWxsLVByZS1DdXRvdXRzLkNvbWJpbmVkLmpwZyIsInNsaWRlc2hvdyI6IjhkNjhkOGEifQ%3D%3D\" href='https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Pre-Cutouts.Combined.jpg'><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"230\" src=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Pre-Cutouts.Combined-768x230.jpg\" class=\"attachment-medium_large size-medium_large\" alt=\"\" srcset=\"https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Pre-Cutouts.Combined-768x230.jpg 768w, https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Pre-Cutouts.Combined-300x90.jpg 300w, https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Pre-Cutouts.Combined-1024x307.jpg 1024w, https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Pre-Cutouts.Combined-1536x461.jpg 1536w, https:\/\/labs.ri.cmu.edu\/moonranger\/wp-content\/uploads\/sites\/24\/2022\/01\/Chassis-Shell-Pre-Cutouts.Combined-2048x615.jpg 2048w\" sizes=\"(max-width: 768px) 100vw, 768px\" \/><\/a>\n\t\t\t<\/div><\/figure>\n\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3e69640 elementor-widget elementor-widget-text-editor\" data-id=\"3e69640\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400\">The shell is trimmed to remove excess material around the edge. Later machining introduces pass-thru cutouts and mounting holes.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>MoonRanger\u2019s carbon fiber composite chassis shell was a triumph of design, process and master craft. Although metal design and machining is much more straightforward, only a composite solution was sufficiently lightweight. A campaign of design, facility development, mold-making, process development, layup, curing and machining created this elegant structural element. The 18\u201d x 17\u201d x 4\u201d &hellip; <a href=\"https:\/\/labs.ri.cmu.edu\/moonranger\/chassis-shell-fabrication\/\">Continued<\/a><\/p>\n","protected":false},"author":28,"featured_media":587,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[25],"tags":[],"class_list":["post-569","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-mechanical"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.5 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Chassis Shell Fabrication - MoonRanger<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/labs.ri.cmu.edu\/moonranger\/chassis-shell-fabrication\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Chassis Shell Fabrication - MoonRanger\" \/>\n<meta property=\"og:description\" content=\"MoonRanger\u2019s carbon fiber composite chassis shell was a triumph of design, process and master craft. Although metal design and machining is much more straightforward, only a composite solution was sufficiently lightweight. A campaign of design, facility development, mold-making, process development, layup, curing and machining created this elegant structural element. 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