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TMann

New Canard Design - Oshkosh 2016

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I was offered a spot on the team that is doing the Vacuum Infusion demo this year at Oshkosh. Talk about a learning opportunity!!!

It will be a new canard design that should prove to be a screamer.
 
All of the components will be fabricated onsite over the course of four days (Mon.-Thurs.)
This will be located in the big tent next to the Warbird Replica building.
 
It’s not often that we get to see the birth of a new Canard design.

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A correction on the timing of this event:
We are setting up on Monday and the actual demo will run Tuesday thru Friday.

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Some additional information regarding the upcoming Vacuum Infusion Demo being presented at Oshkosh.

This was in Composites World.

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I spoke with the lead for this project over the weekend.

​They are on track to ha​ve everything ready in time for Oshkosh.

​Here's a picture of the plug for the bottom have of the fuselage & strakes in the mill.

 

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That's a lot of dust and one rather large CNC machine.

 

Should be interesting once these people identify themselves.

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That's a lot of dust and one rather large CNC machine.

 

Should be interesting once these people identify themselves.

 

No secret. It's Jeff Kerlo (Raptor-Aircraft.com) and Russ Emanis (InnegraTech.com) http://www.innegratech.com/#!Advanced-Infusion-Demonstrations-at-EAA-AirVenture-Oshkosh/bylq7/574461110cf2192cec04a752

 

While this project is a totally independent enterprise they are using the CNC currently located at Raptor Aircraft to mill out the plugs.

It was formally owned by Lockheed Martin. ​I have additional progress pictures but I'll wait until they are further along when it will be more identifiable.

 

The design was created back in 1995 by Jeff. Later a 4 place version was created and built as the Orion and still later the Phoenix. So the design does have some extensive flight time.

 

 ​Russ worked on the Vacuum Infusion effort at Lockheed Martin when they were building the F-22 Raptor.

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Just a reminder.....
In two weeks we should have completed our project at Oshkosh with the reveal occurring on Friday morning, 7/29.
Looking forward to seeing you there. 

 

                                     

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Will be interesting to see, although I won't be there on Friday.  I'll be rooting for success regardless.

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For those who are interested in learning more about Vacuum Infusion, here is the schedule.

Advanced Composite Infusion
Monday, July 25 · 4:00 PM - 5:15 PM
Forum Stage 5

Advanced Composite Infusion Demo 1
Tuesday, July 26 · 10:00 AM - 4:30 PM
Replica Fighters HQ

Advanced Composite Infusion Demo 2
Wednesday, July 27 · 10:00 AM - 4:30 PM
Replica Fighters HQ

Advanced Composite Infusion Demo 3
Thursday, July 28 · 10:00 AM - 4:30 PM
Replica Fighters HQ

Advanced Composite Infusion Reveal
Friday, July 29 · 10:30 AM - 12:30 PM
Replica Fighters HQ       

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Where is this built at? I looked around today at airventure and didn't see it..I would love to check things out tomorrow

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Where is this "Fighter Replica HQ" at? I couldn't find it either.

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I finally managed to locate it... exactly where it was supposed to be.

 

This is a very real endeavor and one to look forward to.

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Well it was quite an experience and learning opportunity.

I got to Oshkosh Sunday around noon in time to help setup the tents where the demo was going to take place.

 

Monday was spent sealing and the molds (7 coats) and then adding another 7 coats of release.

 

Tuesday and Wednesday were spent installing the actual dry fabric and core materials. Those who were there can confirm, we experienced the typical EAA event weather and it did rain ..... a bunch on Wednesday.

 

Thursday started out raining at 8:15 AM. Temp was not as desired. We had 8 molds that we were infusing. The first four were using a urethane based resin system. This was used on the Star Lite aircraft fuselage. The Endurance epoxy system was used for the new canard design. All materials were donated by several different sponsors. One of those products was a combination peel-ply and flow media. We had this in the first four molds for the Star Lite. We discovered that it would not hold up when using the urethane resin.

 

In reality, this is the best situation when doing a demo like this. If everything goes right, you never learn the techniques to resolve the issues as they came up. Russ Emanis showed how to identify problem areas and then resolve them.

 

So after identifying the conflict between the urethane resin and the flow media, we set about pulling the bags off the other three molds and reverted back to the proven Greenflow and peel-ply. The parts were re-plumbed and we built new bags. By now we were getting pretty proficient at doing this but after all, we needed to get 7 more parts to infuse.

 

So of course it starts raining again. At this point we have 4 of the 8 infused.

Work continued until 10:30 to get all 8 infused. After the second wave of rain the temperature really dropped.

 

Friday morning comes and the parts are too green to de-mold. There was a review of everything we did during the course of the week. Once the sun came out, we moved the molds out from under the tents so they could warm up. By late afternoon they were pretty much cured.

 

Saturday morning the parts were de-molded and on display.

A picture of the upper fuselage half is pictured below.

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So here's what we have:

We built the parts in a tent in really crappy weather conditions using new molds that had never had parts pulled from them and still came up with some beautiful parts.

 

Imagine what we could do in a controlled environment.

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​As you can see by the photo below, the flanges have not been trimmed off and the flow media & peel ply have not been stripped off yet.
The upper and lower portions of the fuselage are just setting in place to get a feel for how this is going to look.

The weight (as pictured) is 26 lbs.
Of course this does not include the bulkheads, instrument panel, landing gear, etc., but those are pretty tough numbers to beat.

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Edited by TMann
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Hot damn, can't wait for the prototype to fly!  

 

Does that 26 pounds include plexiglass (I can't tell if that's plexi or leftover from the mold)?

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 That is just fiberglass and will be removed and replaced with plexi-glass.​

They did it this way at Oshkosh so you could get an Idea as to how the finished product will look.

Also of note, in production, the mold will be sprayed with an epoxy based primer and allowed to tack up prior to loading the mold with fabric. Once it is infused, the primer becomes the exterior face so no filling and sanding micro and no pinholes.

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