9/11/22 Risk Reduction

Colin Szeto

Objective was to verify the feasibility of the assembly and dimensions of the motor guard around the

physical motor before laser cutting more expensive material. With no easy access to a laser cutter,

representations of the different motor guard components were laid out in 8.5 by 11 sectors to be printed

out and stitched together for 1:1 scale templates. These templates were used to guide cutting out

the designs from foam core material.

This layout of the motor guard components was created in AutoCad. The red line represented the

outline of the parts to be cut, the purple lines represented the edges of the paper, the yellow boxes

were for page alignment. The team was unable to print out each section individually. 

The layout of the parts was replicated in Adobe Illustrator. Artboards were placed next to one another.

This enabled splitting the design to be printed out on 8.5 by 11 sheets of paper.

8.5 by 11 pieces of paper taped together

The foam core was roughed out to the general dimensions of the design to enable multiple people

working in parallel. 

Zoomed into the capping ring. 

Zoomed into the intermediate ring.

In this template there are 6 pieces of paper stitched together. The template began to fall apart when we

started to cut away the material. 

For circular designs we will need to center the circles on the intersection of 4 pieces of paper.

This reduces amount of joints of paper and provides a more robust template to cut around

The negative space of the parts that were not required to be kept were darkened. This communicated

essential features versus alignment features of the individual pieces of paper

Here was all the material that needed to be removed to hit the desired geometries

Here was the final installation of the risk reduction model onto the motor

Isometric view of the foamcore motor guard

Lessons learned from the risk reduction:

1. The motor geometry is curved, this caused deflection in material

2. The small inner ring was unable to be installed in one piece. Current installation required the inner ring to be cut into two pieces to be installed into the assembly

3. The two smaller ring distance needed to be shorted to reduce the forward and backwards slop due to the vertical airfoil not adequately supported