US SKA TDP Hydroforming Production Cost Rev B 12m Primary & Support Structure US SKA Antenna Working Group Meeting May 7, 2009, Los Angeles, California Matt Fleming Contributions from Jack Welch Roger Schultz Sandy Weinreb Gerry Harp

TDP AWG meeting, Los Angeles, Matt Fleming slide ‹#› of 27 Major Points to Consider In order to compare reflectors the support has to be included. Hydroformed reflector cost is mostly material. Tooling cost gets lost in this project. An offset is 16% more area. 12m has not been done before. Previous 6m reflectors were 4.8mm thick, 12m will be 3.0mm

Hat Creek Assy TDP AWG meeting, Los Angeles, Matt Fleming slide 3 of 27

SKA Assy TDP AWG meeting, Los Angeles, Matt Fleming slide 4 of 27

Direct Unit Price Easiest to Estimate TDP AWG meeting, Los Angeles, Matt Fleming slide 5 of 27 Direct Variable Per Unit Direct Fixed Total Units Total Unit Cost Direct Unit Cost Unit Price Raw material Incoming freight Direct Labor Consumables Packaging Engineering Tooling Process development

Total Unit Cost Best for comparison TDP AWG meeting, Los Angeles, Matt Fleming slide 6 of 27 Total Unit Cost Direct Unit Cost Indirect Fixed Total Units Direct Unit Cost Unit Price Facilities, Utilities, Rent, Insurance, Management, Purchasing, Training, Repairs, replacement.

Unit Price Hard to Estimate TDP AWG meeting, Los Angeles, Matt Fleming slide 7 of 27 Margin Total Unit Cost Direct Unit Cost Unit Price Total Unit Cost Profits Project Proposals Marketing Investments Shareholder dividends

Okay Assumptions First TDP AWG meeting, Los Angeles, Matt Fleming slide 8 of 27

A Peak at Final Results TDP AWG meeting, Los Angeles, Matt Fleming slide ‹#› of 27

Direct Variable Costs Summarize by Stations TDP AWG meeting, Los Angeles, Matt Fleming slide 10 of 27

Step 1 Detail by Station TDP AWG meeting, Los Angeles, Matt Fleming slide 11 of 27

More Detail by Station TDP AWG meeting, Los Angeles, Matt Fleming slide 12 of 27

More Detail by Station TDP AWG meeting, Los Angeles, Matt Fleming slide 13 of 27

Summary Direct Variable Costs TDP AWG meeting, Los Angeles, Matt Fleming slide 14 of 27

Step 2, Production Rate Needed TDP AWG meeting, Los Angeles, Matt Fleming slide ‹#› of 27

Step 3, Direct Fixed Costs TDP AWG meeting, Los Angeles, Matt Fleming slide 16 of 27

Final Results Again TDP AWG meeting, Los Angeles, Matt Fleming slide ‹#› of 27

Reflector & Support TDP AWG meeting, Los Angeles, Matt Fleming slide 18 of 27

Dedicated Facility matched to production rate TDP AWG meeting, Los Angeles, Matt Fleming slide 19 of 27

6 m ATA Primary TDP AWG meeting, Los Angeles, Matt Fleming slide 20 of 27

6m JPL Symmetric TDP AWG meeting, Los Angeles, Matt Fleming slide 21 of 27

Inspection ATA Secondary TDP AWG meeting, Los Angeles, Matt Fleming slide 22 of 27

Test of Flash Projected Targets TDP AWG meeting, Los Angeles, Matt Fleming slide 23 of 27

John Andersen & First Shipment TDP AWG meeting, Los Angeles, Matt Fleming slide 24 of 27

Surface RMS at 12m ? ProjectDiameterMfg rmsGrav rmsWt lbs ATA6.1m 29.2m²0.25mm0.70mm1,400 JPL6.0m 28.3m²0.20mm0.27mm TDP12.0m 113.1m²1.50mm5,814 CART Mk 110.0m 78.5m²1.20mm CART Mk 210.0m 78.5m²0.54mm0.86mm XDM15.0m 176.7m²1.80mm KAT 712.0m 113.1m²1.00mm ASKAP12.0m 113.1m²1.00mm Mounted with gravity paint 1/20 Previous 6m reflectors were 4.8mm thick, 12m will be 3.0mm Offsets have less curvature 0.36mm

6m ATA Early TDP AWG meeting, Los Angeles, Matt Fleming slide 26 of 27

Primary 12 TDP AWG meeting, Los Angeles, Matt Fleming slide 27 of 27

2.4m ATA Early TDP AWG meeting, Los Angeles, Matt Fleming slide 28 of 27

Secondary 12 TDP AWG meeting, Los Angeles, Matt Fleming slide 29 of 27

Primary Reflector Costs Just Beginning to Learn ProjectDiameter$ / dishWt lbs$ / m²$ / lb ATA m 29.2m²24,6001, ATA m 29.2m²13,7001, TDP12m 113.1m²29,4515, CART Mk 210.0m 78.5m²50, ASKAP12m 113.1m² KAT712m 113.1m² TDP AWG meeting, Los Angeles, Matt Fleming slide 30 of 27 ATA -350 reflector original bid $8,300 at 12% total cost. ATA-42 Most recent price is $19,200 at 25% total cost These are not final confirmed figures. Some of these numbers are guesses.

Antenna Costs Just Beginning to Learn ProjectDiameter$ / antWt lbs$ / m²$ / lb ATA-426.1m 29.2m²78,0004,5002, ATA m 29.2m²66,0004,5002, ASCAP-3612m 113.1m²200,00066,1401, KAT7-8012m 113.1m²300,00042,0002, TDP AWG meeting, Los Angeles, Matt Fleming slide 31 of 27 ATA -350 reflector original bid $8,300 at 12% total cost. ATA-42 Most recent price is $19,200 at 25% total cost These are not final confirmed figures. Some of these numbers are guesses.