The SPIRIT Project at Penn State
Structures Team

Deckplate Fabrication:

Composite Layup
Curing
Waterjet Cut
Insert Installation
Intergration

The deckplate group successfully fabricated 3 (of the 12 needed) sandwich composite deckplates. Although the layup process takes roughly 20 minutes per plate, extra time was given to ensure the procedures were followed correctly. Keith Soldavin a SPIRIT alumni who fabricated the SPIRIT II deckplates in 2002, offered his own equipment/composite lab and expertise.

A stack of 6 honeycomb squares

Cutting out the honeycomb material out with a razor blade

Pouring epoxy onto the first carbon fiber ply

After the first three plys have been made, the honeycomb layer is next

Cutting off the excess material so it will not be cured within the vacum.

The first three plates have been layed up, next they will be put in a vacume which will
suck all the excess air bubbles out.

Sealing the vacume pump valve.

The three future ESPRIT deckplates will be left in a vacume for 24 hours, and then
baked for a period of 8 hours.

Waterjet Cutting.


Deckplate #2 and #3 of 9

Pplastic inserts which will disipate the stresses around bolt holes

Installing the inserts

Installation

Intergration

Great appreciation is given to Keith Soldavin for the use of his personal lab and expertise
Contact us for more pictures and more information about the process.