1. 2008-03-15 Matt Fleming Hydroformed Reflector Time & Materials Cost Estimate SKA US TDP Matt Fleming 2008-03-15

2. Matt Fleming Purpose This presentation is intended to estimate the cost of a hydroformed reflector system for use on a multi antenna radio telescope array. The reflector system is composed of several parts and these parts are different for various candidate technologies. A typical system includes the reflector surface and some support system that carries back to the elevation axis and drive attachment points. This exercise is structured in a way that will allow other candidate reflector manufacturing processes to be compared. It examines the process equipment, materials & tasks attempting to identify costs for each. The hydroforming process is well known in the metal forming industry. It uses a fluid, under pressure, to form metal sheet material onto or around a mold or pattern. Care has been taken not to disclose any information proprietary to any individual entity engaged in this business.

3. 2008-03-15 Matt Fleming Elements of Part Costs Any manufactured device has the following cost elements that need to appear somewhere in the analysis. –Facility cost ( often covered in labor rate ) –Technology development cost. –Tooling or equipment cost ( per process ) –Setup & adjustment costs ( per batch ) –Material & Labor cost ( per part ) –Storage & trasportation costs ( per batch )

4. 2008-03-15 Matt Fleming Surface Material Diameter ( material used )12.2meter Thickness0.25inch Weight ( 0.098 )4,439lbs Material price2.40$ / lb Blank cost$10,654 Stiffener cost$2,273 614 lbs 0.188 So how thin can we make it ?

5. 2008-03-15 Matt Fleming Forming TasksMtrlLaborTimeWorkers Raw material & handling.33102 Metal cutting process.$20100601 Welding Process.$20300603 Surface texture process.$80133402 Blank installaton process.67104 Forming process.150452 Part removal process.133204 Inspection process.$20100601 Trim deburr.$1067202 Storage process.$4050152 Repeat prep & cleanup.167205 Total forming cost:$190$1,3006hrs

6. 2008-03-15 Matt Fleming Tooling Costs based on educated guesses Coil equip15,000 Cutting equip35,000 Welding equip45,000 Texture equip32,000 Press ( no mold )500,000 Custom Mold1,420,000 Lifting fixtures8,000 Inspection table7,000 Transport carts7,500 Storage racks12,000 Shipping fixtures26,000 Total forming equip$2,157,500 See separate slide Really big guess

7. 2008-03-15 Matt Fleming Mold Cost Estimate inputs are in green cool units Assume Improved design this is the big guess ratio Diameter6.112.0m1.97 Height1.22.4m1.97 Cost 568,000 1,420,000$2.50 Volume1401068cu-m7.61 Weight 47,000 188,000lbs4.00 Density 335 176cu-m / lb0.53 Rate12.097.55$ / lb1.60

8. 2008-03-15 Matt Fleming Hydroformed Reflector Assy Costs UnitsCost12m = 452m^2 1 3,550,417 7,848.14 10 375,667 830.41 50 93,467 206.61 500 29,972 66.25 2500 24,328 53.78 5000 23,622 52.22