1. P09231 MSD I Winter 20082

2.  Matt Greco: Project Manager  Shawn O’Neil: Lead Engineer  Will Pisarello: Electrical Systems Engineer  Phil Davenport: Industrial/Process Engineer  Brian Lindquist: Industrial Engineer/Procurement Specialist  Eric Lannan: Airframe Structural engineer

3. Manufacturing Procurement Assembly Processes Balsa Airframe Stiffening of wood airframe Composite Reinforcement Surfaces Propulsion Linkages Communication Control System Onboard telemetry Control System Monitoring GPS Positioning Data Acquisition A-D Converter Onboard Memory Storage Payload Interface

4.  Chord = 8”  Span = 5’  Aspect Ratio = 7.5  AOA = 8º  Camber = 8.6%  Thickness = 10.125%  Lift = 10 lbf

5.  Chord = 6.2”  Span = 25.375”  Aspect Ratio = 4.093  AOA = 8º  Camber = 0%  Thickness = 12%  Lift = 1.7 lbf

6. 1. Airframe saved as.STP file in TurboCAD 2. File of the entire airframe assembly is imported into Pro/E 3. Sub-assemblies are saved as.IGS files 4. In ANSYS an.IGS file is imported

7. 5lb 10lb y x Balsa Material Properties Young’s modulus 1130 – 6000 Mpa Shear modulus 100 - 500 MPa Tensile strength 0 - 75 MPa Compressive strength 3.5 - 27 Mpa Material properties from Matbase.com. http://www.matbase.com/material/wood/ class4-5-10-years/balsa/properties

8. ObservationEvaluationRecommendation Laser cut parts were processed to tighter tolerances than anticipated All placement notches on jigs were modified via manual sanding Redesign jigs to accommodate larger placement notches Cyanoacrylate (CA) adhesive was more effective in balsa joints than ply joints Absorption and cure times increase for plywood applications Research alternative adhesive or ply material

9. ObservationEvaluationRecommendation Similar laser cut parts are not easily distinguishable Limited etching prevented inexperienced builder identifying parts Assign part number under each sub-assembly in BOM and laser etch each raw piece Alignment of dihedral braces is very difficult The braces are inherently angled, making for difficult alignment Etch alignment lines on each brace for quick visual alignment with wing box

10. ObservationEvaluationRecommendation Formers along fuselage require exact alignment prior to application of stringers Formers must be positioned in 3D space, leading to error in first plane Design a jig for ease of former placement Battery hatch did not assemble as designed Clearance for hatch decreased during assembly of stringers Place block to maintain battery compartment shape during stringer assembly

11. - Lithium Polymer chosen for high energy density - Modular System - Single pack, ~10min Flight time

12. - COTS Switching regulator converts Battery / Motor voltage to 5v - 12.5W minimum available from the BEC for additional onboard electronics

13. Real Time - Altitude / Airspeed -Temperature - Servo Voltage/Position Data - GPS Two additional onboard ADCs for future sensor testing.

14. Enables onboard control switching between two pilots or a single pilot and an autonomous system Uses: - Autonomous system testing with pilot backup - Control ‘hand off’ between pilots a significant distance apart for extended range flights Working prototype. PCB design has begun. Design Review 2/13/09 ~$50 total per system.

15. 1/19/2009 $ 276.18Tower Hobbies, remaining mat $ 93.00ACP-Composites $ 18.00Digikey, control switch 1/28/2009 $ 75.20National Balsa 1/29/2009 $ 104.76HobbyKing, 4 batts $ 93.30HobbyKing, electronics $ 50.00FoxLite, laser cutting 2/6/2009 $ 66.05Performance Hobbies, misc $ 9.77Home Depot Total As Of2/10/2009 $ 1,414.23 Airframe ASegregated Budget Raw Airframe with motor ComponentQtyPiece PriceTotal Price Motor HXT42-601 $ 35.79 Landing Gear1 $ 25.27 Linkages, Connectors, Hinges, misc1 $ 50.00 Balsa Stick, Sheet1 $ 16.50 Laser-Cut Balsa1 $ 25.00 Propeller1 $ 1.00 Covering1 $ 5.00 Composite Material1 $ 5.00 Subtotal $ 163.56 Electronics Servo S30102 $ 19.99 $ 39.98 Receiver Supreme 28 LXKYK31 $ 39.99 Servo S31142 $ 14.99 $ 29.98 Speed Controller1 $ 16.79 Battery eliminator circuit1 $ 19.95 Subtotal $ 146.69 Airframe without batt $ 310.25 Battery Lithium Polymer2 $ 19.99 $ 39.98 Telemetry (Optional)1 $ 627.97 Total $ 350.23 w/Telemetry $ 978.20