Micro Gravity Repair Facility
This is the Micro Gravity Repair Facility designed by my group and I for the NASA studio at RISD. The point of the assignment was to design and build a full-scale mockup of a repair facility for a long-term exploration mission to the far side of the moon, a comet, or Mars.
The drill press design employs the same motor as the 80-20 cutter and just like the 80-20 cutter the drill press can be broken down and stored away when not in use. The drill press also hocks into the 80-20 farm so adjusting it for different heights and different pieces is relatively straightforward. It has a built in depth gage enabling the user to set a certain depth and make multiple holes at the same depth without having to measure each individual hole. There are also two chip collector connectors on the drill press. The top one collects most of the chips while the bottom one collects the chips that are created when a through hole is drilled. The top chip cover is also capable of moving up and down with the drill so that it stays in contact with the surface of the material creating a seal and preventing chips from escaping into the ships atmosphere.
The 80-20 cutter is a saw design that uses the principals of a table saw to provide clean and straight cuts that need minimal cleaning after they are done. This particular saw employs a 6 inch 80 tooth blade specifically made for aluminum cutting. Due to the conductive nature of aluminum the saw does not include safety features like SawStop but the time that the actual blade is exposed is minimal meaning that the chance of injury is very small. There are three points of suction on the saw providing a very clean cutting process. All the chips are collected and sucked directly into the chip compactor.
The sheet metal manipulation modules are stored in the ground. When the actuation towers are up, the modules can be attached to the towers. The modules work in synchronicity to create a sheet metal roller, a sheer, a computerized break, and a press. The top module is constructed in a matter that allows the inside of the module to contain the press, sheet, and bend, while the outside housing serves as the 3rd roller for curving sheet metal. The roller can be stored in the floor when it is not in use.
The process relied heavily on full-scale models. Before the final model was constructed we went through two full-scale models and one small model. There was invaluable data collected from the full-scale models which would have been impossible to see from smaller models. The initial models were assembled with cardboard and hot glue. The final model was made from wood, 80-20, and foam core.