This document details any ideas and design goals that the Aeroshell system is interested in implementing for the 2024-2026 car.
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- It is difficult to find the location to cut the lip for the top shell, bottom shell, and canopy + cut the holes for the wheels, windshield, lights. This is due to the fact that the canopy has no reference points.
- Make the angles sharper
- Make some kind of indent or marking in the molds
- Look into going straight from foam to CF, using split mold manufacturing or similar techniques
- When demolding the bottom shell as well as canopy, we have had issue pulling it out due to the walls of the shell being vertical.
- Have a draft angle
- Make a non concave fiberglass mold
- Daybreak's CAD does not have the correct thicknesses for the composites
- Have the design lead and the manufacturing lead for aeroshell have a talk about what materials they want the car to be made of as well as the amount of ply to use. The manufacturing lead will perform test layups to find the hypothetical thickness of the composite and the design lead will edit the the CAD so that it is accurate to the thickness that the manufacturing.
- Currently the top shell and the bottom shell have the same edge, so the top shell edge is only resting on the bottom shell edge.
- Make a horizontal lip on the bottom shell that goes outwards. The top shell will be wider than the lip on the bottom shell and it will rest on the bottom shell's lip
- This is most feasible if we do a three wheel car. If we do this if the bottom shell is as wide as it is currently then our car will be way too fat.
- Top shell may have to be manufactured in two pieces.
- Make a horizontal lip on the bottom shell that goes outwards. The top shell will be wider than the lip on the bottom shell and it will rest on the bottom shell's lip