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Design Process and Documentation |
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At first glance, the design of the SAT seems overwhelming and extremely
involved in many aspects of the design process. When a closer look
is taken at previous models and their need for improvement, the first
impression becomes nothing less than a lasting one. This design must
include capacity for intense shock and vibration, weight requirements, a
rigorous immersion test, design for cost and manufacturing, injection
moldable, UV stability, EMI shielding, topped with aesthetics and
ergonomics. |
Milestones
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most difficult part of the entire design process was designing for the immersion
test, followed by intense shock and vibration requirements.
Material Selection played a big role in passing these tests. For
this reason, LEXAN9330 was chosen to be the
material matrix of the SAT. This particular version of Lexan from geplastics.com
combines the characteristics such high ductility and toughness at
temperature extremes as well Ultra-Violet stability and the capability for
Electromagnetic Shielding. Stereolithography
is the process used to fabricate a prototype. This process involves
converting CAD files directly into a tangible prototype in a matter of
hours. Injection molding played a significant role in the
refinements of the prototype towards the finale of the project.
Constant thickness, gussets, fillets, and rounds among other properties proved to be
quite important in the fabrication of a finished product free from warped
components caused by slow-drying, thickspots. |
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Testing Procedures
 | Extreme Temperatures |
| Solar Loading |
| Humidity |
| Salt Fog |
| Rainfall |
| Sand and Dust |
| Vibration |
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