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Ultra light structure - Study No 2. Balsa and polycarbonate tubes assembled with rigid corners. 4 motors are located at the middle of the bottom edges, 4 motors at the middle of the vertical edges. This model did not pass the structural resistance tests.
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Ultra light structure. Study No 2. Basswood and polycarbonate. Detail of the corners.
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Tubes for the crossing of air fluxes in the rigid cubes, at the corner of the structure, for studies No 2, 3 and 4. Balsa plywood, polycarbonate, PETJ polymer.
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Studi No 1. Prototype structure. Extruded polystyrene (styrofoam). Despite of its structural qualities and low cost, this material was not selected for the next protoyptes because of its instability in time.
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Benchmark test for ducted fans, Summer 2003. A small cart mounted on wheels with bearings moves along metal rails. réalisé dans le courant de l'été 2003. It is attached by a spring to the end of the rails. When the motor runs, the spring lenghthens proportionally to the thrust.Motor : Jeti Phasor 400 within a 90mm ducted fan made of polycarbonate and carbon fibers.
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Benchmark test for ducted fan, front view of the cart.
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Bottle of water calibrated at 25g intervals for mesuring ducted fans thrust measurements.
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Welding iron modified to weld mylar film. The wider plate is used to distribute the heat on a larger surfaced, thus decreasing the welding temperature.
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Test on a mylar film bladder inflated with air, in order to check the quality of the welding work and the diffusion rate through the film. . |
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Structural study No 2. Templates for the cutting of structural elements of the horizontal beams. Left, lower template (MDF). Right, upper template (aluminium). Bottom, the final element (balsa plywood).
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Structural study No 2. Templates for the cutting of structural elements of the vertical beams. Left, lower template (MDF). Right, upper template (aluminium). Center, the final element (balsa plywood).
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Structural No 2. Templates for the cutting of the pieces located at the end od the vertical beams. Left, upper template (aluminium). Right, lower template (MDF).
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Structural study No 2. Detail of the end of a horizontal beam, showing the balsa plywood plate for assembling.
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Studies No 2, 3 and 4. Vacuum-molded motor shell, PETJ-type clear polymer. Studies No 2, 3 and 4. Holes on the shell periphery ("cheater holes") allow air intake at the middle of the shell, thus decreasing the load on the motor.
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Study No 1.Vacuum-molded half motor shell. White PETJ-type polymer.
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Study No 3. MDF template for the construction of the beams.
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Study No 2. Structural resistance test on a polycarbonate-balsa composite beam. The beam is attached to a rigid frame by its ends. A thermoshrinkable film is fixed along the edge, then stretched with a heat gun. The important arrow at the center of the beam reveals a very weak performance.
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Study No 3. Balsa wood beam, detail. The beam widens at the center in order to couneract the tension of the thermoshrinkable films.
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Study No 4. Structural resistance test on a composite beam (balsa and bassswood). The performance of the beam is very good (very little deformation at the center), but the fragility of the balsa makes it unpractical to manipulate and use. The weight of the 1500mm beam is 100g.
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Study No 4. Structural resistance test on a composite beam (balsa and bassswood).
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Loading test of the thermoshrinkable films.The film is loaded with a mass of water equivalent to the maximal weight of the Mascarillon, in order to verify the performance of the adhesive films that are used to fix it, the resilience of the membrane, and to check the maximal deformation on the upper face of the cube.
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Loading test of the thermoshrinkable film (view from below). The stretched film is loaded with 4500g of water. . |
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Study No 4. Details of a corner of the structure. Composite beams (balsa and basswood).The cube at the corner is made from balsa plywood. . |
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Study No 5. This structure is used for the M180 prototype. Model at 1/10 scale, balsa. The diagonals pieces are not installed in order to visualize the deformations under different kinfs of load. The real-size prototype is made of basswood; attaches are made from nylon and steel. . |
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Study No 5. Final structure model, balsa, scale 1/10. Illustration of the deformations.
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Study No 5. Leveling and calibration of the mounting bench for type 5 beams. |
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Study No 5. Assemblage of a type 5 beam on the mounting bench. The beam, entirely made from basswood, weighs about 80g for a length of 1500mm.
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Study No 5. Completed type 5 beam. A cyanoacrylate glue is used for assembling. Latex gloves are mandatory for this work. |
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Structural study No 5 (last to date). Orthogonal template for the assamblage of the beams at the Mascarillon corner.
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Study No 5. Type 5 basswood beam. Details of the inside. The cross section of the beam is an equilateral triangle. Two 20mm wide basswood pieces recreate 90o angles at the edges. |
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Study No 5. Two type 5 basswood beams. All pieces have been cut from a large 50mm x 120mm beam. |
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Study No 5. Mounting of three type 5 beams. Left : Guillaume Credoz, co-researcher. Right : Jean-Bruno Valiquette, research assistant.
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Study No 5. Three type 5 beams ready for quality checking. |
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