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After still having major problems with waterproof design, the idea is to start a new fuselage design from scratch in fiber composite technology. This promises the following advantages

• Waterproof material - foam is not water resistant
• Possibility to adapt the geometry to our requirements, e.g. camera connection
• Thin material requires only small holes for camera without obstruction view
• Fiberwings will pave the way to possible solar cell support for extending range

The big drawback is missing experience with aircraft design and fiber technology.

• Design a negative lamination mould from Rampf MB-0600 Polyurethan material by milling
• Mill: Step-Four Xpert 1000 S in the Holzwerkstatt Modellbau
• CAD: Onshape, CAM: Deskproto, NC: XpertMill (Holzwerkstatt)
• Glueing of the Rampf MB-0600 for L shape: Rampf EP2306 resing + EH-2904-1 hardener
• Surface Sealing of the MB-0600 material with Münch Mikon 399 MC sealer
• Release Agent (Trennmittel): Münch Mikon® Mirror Wax liquid W-99+
• Alternative Release Agent: RAKU® TOOL AC-9103
• Laminate 2 layers 160g/m2 GFK (R&G)
• Epoxyresin from R&G

The Deskproto CAM software needs some RAM depending on the detail level. The Deskproto Software is .

On 15./19./20.12.2020 we did a first milling test with a small MB-0600 test block

• Testblock size: 250mm x 146mm x 75mm
• CAD:
• Ergebnisse des Frästests
• Deskproto Design Data and GCode Files

The milling was done aiming at best milling results. So the distance between milling paths and z distance was set to 0.06mm. Schlichten took 2h 50min for the “Z Konstant” strategy and 7h for the “Überkreuz” strategy.