This document is separated in to two sections, the test specification and the test procedure.
The test specification section defines the purpose of the test, the test approach, the item under test, test sequence, test facility, pass/fail criteria, required documentation, participants and test schedule.
The test report section gives directions for conducting a test activity in terms of description, resources, constraints and provides detailed step‐by‐step instructions for conducting test activities with the selected test facility and set‐up.
This document is written to define the technical specifications of the mold intended for the manufacturing of a composite nosecone. This mold will be 3D-printed and used as a support for the lay-up and polymerization of the composite. It aims to ensure dimensional accuracy, mechanical resistance, and compatibility with the chosen manufacturing process.
The objective of this document is to provide a detailed description of the technical requirements, materials, manufacturing process, and validation criteria of the mold. It is intended for engineers, technicians, and team members working on the fabrication of the nosecone. By reading this document, they should be able to understand the mold specifications, assess its feasibility, and follow recommendations for its manufacturing and use.
This document covers aspects related to the design, manufacturing, and validation of the 3D-printed mold. It includes geometric specifications, recommended materials, 3D printing parameters, and necessary performance tests.
The system concerned is the mold used for the fabrication of the nosecone of a rocket. This mold must be designed to ensure a proper fit and optimal surface finish while being sufficiently resistant to withstand the mechanical and thermal stresses of the manufacturing process.
The book Composite Airframe Structures by Michael Chun Yung Ni, explains the methods to apply Composites.
There are 3 main types of types of documents which relate to testing activities.
The Test Specification Plan (TSP) for the 3D-printed nosecone mold aims to ensure that the mold meets the design and manufacturing requirements. The tests will focus on dimensional accuracy, structural integrity, and compatibility with the carbon nosecone manufacturing process. We will also test the interface between two parts of the mold since the mold is composed of 3-4 parts.
We will test 4 materials in priority : PETG HT 100, PET UF 15,PC, PC CF to see which one deform less after the polymerisation process in the autoclave.
The impression 3D of the first part of the mold was launched Friday 07/03.
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Make a list of all of the requirements which you aim to verify during the test, if a requiremnt does not exist yet, contact your TL or SE. It is important to link all of the requirements which you aim verify as it will show up in the Verification Control Document which shows whether or not each document has been verified and how each requirements aims to be verified.
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We printed only a part of the mold to test the junctions between the parts of the mold. We will print the whole mold once we know that our technic is good.
We will print two parts of the mold and ensure that the junctions between them hold firmly to prevent any slight movement. Once we have a proper setup, we will apply some consumables to better understand the techniques. We will also sand the structure to ensure a smooth finish and improve the overall fit of the junctions.
We will then compare the mecanical properties of the different molds made in different materials (PETG HT 100, PET UF 15, PC and PC CF) to see which one will deform the less once it has been through the polymerisation process.
The temperature resistance of these materials in an autoclave for six hours varies depending on their thermal properties. PETG HT 100 has a glass transition temperature (Tg) of approximately 100°C, meaning it may deform if exposed to higher temperatures. PET UF 15 is rated for 110°C and should remain stable under these conditions. Polycarbonate (PC), with a Tg of around 147°C, can easily withstand 110°C without softening. PC-CF (Carbon Fiber Reinforced Polycarbonate) offers increased thermal stability and can resist 110-120°C, or possibly higher. If the autoclave exceeds 110°C, PETG HT 100 and potentially PET UF 15 may not be suitable. The autoclave temperature is around 100 degrees, so they will probably not deform.
The testing activities must be conducted in a controlled environment to ensure accuracy and repeatability. Measurement instruments should be regularly calibrated to maintain precision. The mold components must be handled carefully to prevent any damage before testing. The setup for structural and dimensional validation must be stable to eliminate external interferences.
The sequence of testing activities follows a logical order to ensure accurate and reliable results. Dimensional verification will be conducted first to confirm that the mold meets design specifications before proceeding with mechanical resistance testing. Once structural integrity is validated, surface preparation, including sanding, will be performed to optimize the mold for consumable application. The final stage of testing involves assessing the compatibility of various consumables, ensuring that they adhere properly and function as intended in the manufacturing process. Any modifications required based on test outcomes will be implemented sequentially to refine the mold and its usability. We will maybe put the molds in an autoclave and then compare the different deformation of the molds made in different materials.
The criteria for determining whether the test is successful are based on dimensional accuracy, structural integrity, and material compatibility. The mold will pass the dimensional test if all measured values fall within the defined tolerances. The mechanical resistance test will be considered successful if the mold withstands applied forces without exceeding the maximum allowed deformation. Finally, the material compatibility test will be validated if all applied consumables adhere correctly without causing surface degradation or structural weakening. If any of these conditions are not met, the test will be deemed a failure, and necessary adjustments will be made before re-testing. If possible, I would like to test the mold in an autoclave to see if it withstands the pressure and heat-induced warping.
The PDB Composite manufacturing team will be present, the TL of Structure will probably be present too. We are printing the 2 parts of the mold 07/03
We will test 2 parts of the mold of the Nosecone to see if they fit together well, sand them then maybe put the assemblage into an autoclave.
| Sub-System | Part Name/ID | Type of Part | Version ID |
|---|---|---|---|
| Structure | Nosecone Mold | Prototype | 03.07.25 |
| Name |
|---|
| Emma |
| Gabriel |
| Thomas |
| Florent |
| Zina |
| Sébastien du SPOT |
| Safety Concern | Probability | Impact | Severity | Mitigation | Post-Mitigation Probability | Post-Mitigation Impact | Post-Mitigation Severity |
|---|---|---|---|---|---|---|---|
| Let the mold fall | Low | Low | High | Do not touch the mold when it is hot, move it with caution | Very low | Low |
| Safety Concern | Probability | Impact | Severity | Mitigation | Post-Mitigation Probability | Post-Mitigation Impact | Post-Mitigation Severity |
|---|---|---|---|---|---|---|---|
| Burn | Low | Low | High | Do not touch the mold when it is hot | Very low | Low | |
| Sanding the mold | Low | Low | High | Wear a mask when sanding | Low | Low |
| Done ? | Task |
|---|---|
| Launch printing of the mold | |
| Carefully remove the mold parts from the impression plate | |
| Put the mold's parts together | |
| Start Sanding with a mask on | |
| Apply the consommables | |
| Determine validity of the result | |
| Put the mold part into an autoclave |