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JDEM Focal Plane Assembly

Full-scale Mock upand

Cold Plate Engineering model

Prepared for Michael Levi and Henry Heetderks

JDEM

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Overview

In response to the opportunity to produce a JDEM Focal Plane Model in time for Late October presentation, two scenarios appear feasible:

– 1. Full-scale engineering model of the Cold Plate.

– All aluminum, built in LBL shops

– Identical to Bobby’s design but with relaxed tolerances.

– If we start within the next few days, we get inserted into the job que in time to meet a 20 Oct deadline. (Maybe with time to Black Anodize it)

– ~$7K rough estimate at the moment, but being refined. Some streamlining might help.

– 2 Full-scale concept model of the entire Focal Plane Assembly.

– Plastic, Built in a local prototype shop.

– Probably a high density syntactic foam. Many choices.

– Reworked to eliminate detail and adapt structural details to work in plastic.

– Much lower resolution (tolerance)

– Fast

– $3K-$10 in bite-sized chunks, depending on scope

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Next

• The Engineering Model — Cold Plate Must begin in the next few days.

– To start this option, I need to issue a Job Order to the Shop and give them an account Number, with your approval..

– John Haugrud is now juggling the job que to put us on a high-speed machine, and will need to order material ASAP.

– We both think that some refinement would reduce cost and time.

• The Concept Model --- Focal Plane Assembly Also must begin in the next few days.

– To start this Option, A Purchase Order must be issued to the vendor, also with your approval.

– This may require RFP and response from the vendor.

– With assurance the PO process in in the works, the vendor may be willing to provide advance samples of our parts to get a direct measure of fit, tolerance, finish, and material options, before we commit to the whole assembly..

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Job descriptions

• The Engineering Model — Cold Plate.

– Make 1 Cold Plate as per CAD model xxxxxxxxxxxxxxxxxxxxxx

– Monolithic Aluminum

– Tolerances: IAW best practices for that machine

– If Time allows, apply Black Anodized finish.

• The Concept Model --- Focal Plane Assembly

– Make sample parts or assembly sections to demonstrate fit, finish, tolerance, and material with actual model geometry.

– Adjust model design to optimize production and desired detail.

– Fabricate components.

– Assemble final presentation model.

– If time allows, build or rig temporary display fixtures.

– Note that this is phased process, giving some last-minute control over scope and cost.

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Bobby’s model compared to the Concept model

The following slides show comparisons between Bobby’s model and the Concept Model.

I made gross simplifications by removing details, thickening wall sections, and tweaking radii.

The intent is to make the model robust enough to survive being handled, and simple enough to be able

to make quickly.

The model is modified specifically to be rendered in non-metallic modelling materials in NC machinig stations. Rework is still in progress.

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Cold Plate Engineering Model, Front

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Cold Plate Engineering Model, Back

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Bobby’s CAD Model

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Concept Model

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Concept Model Exploded, front

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Concept Model Exploded, back

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Single Detector Module

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Single Detector Module

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Bobby’s Model Exploded, back

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Bobby’s Model Exploded, front

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Engineering Model

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Engineering Model section

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Engineering Model section

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Concept Model section

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Concept Model section

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Concept Model section

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Concept Model