WaterCopter Plan of Procedures

 The WaterCopter requires a structure to house and protect all electrical and mechanical components needed to create a quad copter capable of sampling water. This Plan of Procedures document outlines all of the materials, parts, and processes that are made or performed to construct the structure. The WaterCopter utilizes an exoskeleton structure made of two Kydex 100 halves, a silicone seal to maintain water integrity, and zip ties to hold the halves together. The Kydex halves thermoform over a positive model of the shell. The thermoformed halves are cut out with a 1/4” flange, which is drilled to produce slots for the zip ties to secure. The seal is cut from a sheet of silicone, slots cut, and sandwiched between the two halves. The assembly secures with zip ties.

Materials List

	Material	Quantity	Specs	Part
M1	Kydex 100	2	2’ x 2’ x .093”	Exoskeleton
M2	Silicone	1	3’ x 3’ x .0625”	Seal
M3	Plywood	2	2.75’ x 2.75’ x .25”	Vacuum Table
M4	ABS Plastic	1 Roll	N/A	Vacuum Form

Supplies List

	Product	Quantity	Specs	Part
S1	Zip Ties	200	White/Black	Exoskeleton
S2	Silicone	1	3’ x 3’ x .0625”	Vacuum Table
S3	Wood Staples	20	N/A	Vacuum Table

Tools List

	Tool	Part 1	Part 2
T1	Drill Press	Vacuum Table	Exoskeleton
T2	Staple Gun	Vacuum Table
T3	Band Saw	Vacuum Table	Exoskeleton
T4	Box Cutter	Seal
T5	Sand Paper	Exoskeleton
T6	3D Printer	Vacuum Form
T7	Vacuum	Vacuum Table	Exoskeleton

Part List

	Part	Materials Components	Supplies Components	Tool Components
P1	Exoskeleton (T/B)	M1	S1	T1, T2, T5
P2	Seal	M2	S1	T4
P3	Vacuum Table (T/B)	M3	S2, S3	T1, T2, T3
P4	Vacuum Form (T/B)	M4		T6

 Plans of Procedures

Part Three Plan of Procedures

1. Using the Drill Press (T1), drill ½” diameter holes into the Plywood (1M3), 12 holes x 12 holes.
2. Using the Band Saw (T3), cut out the center 2.5’ x 2.5’ of the second Plywood (2M3).
3. Lay the Silicone (S2), over the hollowed Plywood (2M3).
4.  Fold the Silicone (S2) over the edges of the Plywood (2M3) and staple the Silicone to the top of the Plywood using the Staple Gun (T2) and the Wood Staples (S3).
5. Connect the Vacuum (T7) to the Vacuum Table Bottom (1M3).

Part Four Plan of Procedures

Vacuum Form (TP4) Top

Vacuum Form (TP4) Bottom

1. Using the 3D Printer (T6) and the ABS Plastic (M4), print the Vacuum Form (TP4)
2. Repeat for Vacuum Form (BP4)

Part One Plan of Procedures

Exoskeleton Top (TP1)

Exoskeleton Bottom

1. Heat the Kydex 100 (1M1) to 350 degrees Fahrenheit.
2.  Place Vacuum Form (TP4) on the Vacuum Table (BP3).
3.  Place Heated Kydex (1M1) over the Vacuum Form (TP4).
4. Turn on the Vacuum (T7).
5.  Press the Vacuum Table Top (TP3) over the Kydex (1M1) and the Form (TP4).
6. Turn off the Vacuum (T7) and remove the Vacuum Table Top (TP3).
7. Using the Band Saw (T3) cut out the .25” flange around the Exoskeleton Top (TP1).
8. Using the Drill Press (T1) drill holes around the flange for the Zip Ties (S1).
9. Repeat to manufacture Exoskeleton Bottom (BP1).

   

   Top View of Exoskeleton Top (TP1)

Part Two Plan of Procedures

Seal (P2) Top

Seal (P2) Magnified

1. Using the Exoskeleton (P1), cut out the Seal (P2) from the Silicone (M2).
2. Using the Box Cutter (T4) cut slits in the zip tie locations.

Assembly Plan of Procedures

Assembly Front View

1. Take the Exoskeleton (T/BP1) and the Seal (P2).
2. Place the Exoskeleton Bottom (BP1) beneath the Seal (P2).
3. Place electronics within the Exoskeleton Bottom (BP1).
4. Place the Exoskeleton Top (TP1) above the Seal (P2). 
5. Secure with the Zip Ties (S1).

   

   Assembly Isometric View