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Our Manufacturing processes involved multiple cutting, joining, material removal and shaping techniques.
All the parts of the shell were handmade by members of the team.
The corners of the base frames are supported by custom made brackets
The corner joints used a combination of chemical bonding and rivets
3M Impact Resistant Epoxy was used instead of traditional welding to join the corners of the frames.
The frame was held in place using corner clamps, rivets and brackets for 24 hours while the epoxy cured
A custom made sheet metal bender was used to form the ribs and panels
The sheet metal bender was able to make highly accurate, repeatable bends
Holes were countersunk so that rivets and threaded inserts in the frame were flush and did not interfere with panel fitment
The ribs were dry fit to the frame to ensure everything would fit together (Left)
M5 Flat Head Pan Bolts were tested in the threaded inserts secured to the frame (Right)
The frame components came together quite easily and was very similar to the designed frame
The panels were traced out onto aluminum sheets then bent to fit over the frame using the sheet metal bender
The panels were made specifically to fit the frame and may have deviated slightly from the CAD models made during the design phase
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