Spaceship Earth

SCML

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An aerospace facility designed and built to leverage distributed, conventional, and additive manufacturing (3D printing) technology.

Summary

Space Cooperative Manufacturing Labs (SCML) is a contemporary ‘fab lab’ based on the latest digital machine tools intended to serve the R&D prototyping needs of Space Decentral projects while supporting itself as a commercial contract fabrication facility. It would be open to the typical range of Maker-oriented services while also cultivating more advanced fabrication capability suited to aerospace and other advanced applications. It may also provide architectural fabrication services in support of Space Cooperative facilities construction and mockup development.


Discussion

The scope of this document is to outline all information needed to visually design a building for Space Cooperative Manufacturing Lab for use on all of our documents / explanations. Site Information Size of lot: 0.5 acres topography: largely flat access to at least one of the following roads capable of handling cargo trucks rail loading/offloading barge loading/offloading Occupancy and Zoning Information Average number of people: Working: 150 Visiting: 45 Students: 20 Permitted uses: Heavy manufacturing Chemical storage Education Tourism List of desired activities to take place in the building, list of requirements that may impact on design: Computer labs inside of the classroom/auditorium Small routers/3d printers inside the classroom/auditorium with a makerspace feel *Size of rockets to be built: * 150 m (492.126 ft) Hardware and equipment (technical): https://docs.google.com/document/d/1gNLbZfgqCJq1yWInvzKbJQsHzFlDwS-X4XKhXMh5H_Q/edit?usp=sharing Mood board: http://twistedsifter.com/2012/05/rooftop-boardroom-with-panoramic-indoor-garden/ Floor Plan Design recommendations passive cooling architecture (https://www.treehugger.com/green-architecture/architect-uses-ancient-techniques-cool-modern-building-india.html) reduces energy consumption adds functionality to the garden/ waterfall aesthetic access to mass transit - dedicated bus stop close to front entrance may decrease required parking square footage increases accessibility for people, generally stacked parking (http://cityliftparking.com/solutions) reduces lot square footage dedicated to parking reduces local heat-island effect from heavily paved areas improved aesthetic on-site stormwater recovery, treatment, and storage large lot area and roof area likely to gather significant volume of water during wet season in many California jurisdictions, on-site capture and treatment already required (by low-impact development/ LID systems) environmentally friendly reduces operating costs can integrate into garden/waterfall concept and add functionality to the aesthetic of it solar roofs and parking shade structures large lot size and roof area likely makes facility less dependent on centralized power production can be net revenue generator in long-term Regulatory notes * U.S.A * ADA compliance * ramps, guardrails, bathrooms, door sizes... * may increase square footage required for various paths. requires elevators for multi-story structures * fire code * requires large rights-of-way and turnaround space for fire trucks * eats away at site square footage * may require additional space around hazardous materials * California * Coastal Commission * adds cost and increases time required for construction to begin * Title 24 - Building Energy Efficiency * sets relatively high standards * modestly increases costs compared to other jurisdictions * Building Code * general municipal * zoning code * varying amounts of flexibility depending on jurisdiction and how many lawyers we have * approved petitions for exemptions are infamously common in Los Angeles * setbacks and easements - the local government restricts property owners’ rights to build at the edges of their property, and in some cases reserves the right to build public rights-of-way (roads, utilities, etc.) within the lot (Los Angeles) parking minimum parking requirements are based on occupancy and type of use minimum required parking square footage can often exceed the first-floor square footage itself building near mass-transit can sometimes grant exceptions to minimums ** Components** * Avionics * Avionics are the electronic systems used on aircraft, artificial satellites, and spacecraft. Avionic systems include communications, navigation, the display and management of multiple systems, and the hundreds of systems that are fitted to aircraft to perform individual functions. These can be as simple as a searchlight for a police helicopter or as complicated as the tactical system for an airborne early warning platform. The term avionics is a portmanteau of the words aviation and electronics. The Avionics department will handle all electro-mechanical assemblies involved. * Propulsion * Liquid Propulsion Systems Design & Integration The Propulsion Systems Design & Integration Division performs engineering development, oversight, and integration of propulsion systems for space transportation applications, ensuring the sustained, safe operations of existing systems as well as the successful development of new systems. New propulsion methods will be built and tested (to a safe degree) here. * Non-destructive testing * Non destructive testing department at SCML will include X-Ray machines, Penetrant inspection tanks, Ultrasonic testing machines, Magnetic particle testing machines,, and everything involved in testing equipment non destructively. This is where rocket parts are tested to make sure there are no internal defects in raw materials, welded assemblies, electrical components, etc. * Destructive Testing * The destructive testing department at SCML will include all of the very loud destructive machines that simulate space atmospheres- Ovens, vacuum chambers, vibration machines, cutoff saws for transverse / longitudinal cross sectioning of welded parts / assemblies, etc. The reason this is outside is because it can generally be a more high risk area, and special clearance should be held to enter this- As well as proper protective equipment by all people entering at all times. * Machine Shop / Welding * The machine shop will be a very important component to SCML- this is where all parts are brought in as raw stock and using subtractive or additive manufacturing, will be transformed into actual space components and assemblies. It is always wise for the welding department to work closely with the machine shop, as they will supplement each other during builds. The main bulk of the machine shop will be CNC Lathes and Mills, with some 3D printers, and manual welding machines. Automated welding machines can be in a separate room. Such as Laser beam welders and electron beam welders. * Rocket Assembly * This is where the heavy stuff is assembled such as Rockets, capsules, and anything that is mainly structural, and not requiring clean room treatment. There should be a large loading gate near the rocket assembly area to get parts out of the shop and out for testing / loading onto launch gear or hangars for storage. * Clean rooms * Clean rooms are where most small components / sensitive objects are assembled. Most are FOD (Foreign Object Debree) sensitive or require very clean environments and humidity/temperature sensitive. * Classroom / Auditorium * The classroom / Auditorium can double as a lecture hall / computer lab, and also as a presentation floor for speakers. The classroom aspect of this will be for classes that are outlined in the following document: https://docs.google.com/document/d/106VvHKPMXnEJpyIeXk_IAH1r4CdhBjdFf7EDsQCRGis/edit * Commons * The commons is where people go to relax on break time, after work, or during free time. Since SCML might have a lot of visitors / classmates, it would be nice to have a very accommodating commons where people can have lunch, purchase food and drinks, socialize, etc. * Gardens / Waterfall * What would the commons be like if we didn't have beautiful scenery? Visually stunning work environments will keep people happy during their shifts/classes. This may be a little overkill when it comes to a manufacturing shop, and i’ve never actually seen this in a real manufacturing shop, but space cooperative is here to change the world one waterfall at a time. * Offices * This is where the HR part of the operation hang out, as well as Engineers, project managers, production control, sales directors, marketing. Document control can also be a part of the office area as well as server rooms and anything that generally needs to stay out of the actual manufacturing shop.
This post outlines some of the necessary equipment that is needed for operation in a successful Manufacturing Shop / Makerspace. See the following link for the price and product websites for a more detailed view of equipment. Capital Investment (Costs for Equipment) (https://docs.google.com/spreadsheets/d/1dsqdzHamHkK3ugARu8wzhG6rS1KeDbILO_7SekMwkwg/edit?usp=sharing) Inspection Equipment Microscopes Vision System with Measurement / Still image capture capabilities Reference Microscopes (High Mag for Visual inspection) SEM (To analyze grain structure) Mass Spectrometer Computer Measuring Machine (CMM) Surface Plates (Calibrated) Height Gauges Dial Indicators Gauge Pin set Gauge Block set Optical Comparator Calipers 6 inch 12 inch Verniers Micrometers 0-1 inch 1-2 inch 2 inch + Digital Camera Subtractive Manufacturing Equipment CNC Mill (5 Axis) CNC Lathe (Live Tooling) CNC Router Conventional Mill Conventional Lathe Surface Grinder Additive Manufacturing Equipment 3D Printer FDM (Fused Deposition Modeling) Metal Sintering Welding Equipment TIG Welder Orbital Welder Electron Beam Welder Laser Welder Resistance Tacking Machine Arc Welder (Flux Core) Laser Etching Machine Testing Equipment UTM (Universal Testing Machine) FPT (Penetrant Inspection) X-RAY (Radiographic Inspection) UT (Ultrasonic Testing Inspection) MAG (Magnetic Particle Inspection) Pressure Testing HLT (Helium Leak Tester) Cutting Equipment Horizontal Band Saw Vertical Band Saw Laser Cutter CO2 (Sheet / Shape Cutter) NdYAG (For Laser Drilling) Water Jet Cutter Sheer Bench Metallurgical Equipment Wet Abrasive Cutoff Saw Circular Sanding Station Wet Sanding / Diamond Polishing Pad Acrylic Potting Materials Fabrication Equipment Dye Press Tube Bender Metal Stamper Timesavers Grinding Machine Avionics Equipment Soldering Iron Digital Multimeter Oscilloscope PCB Mill Maintenance Equipment Handheld Infrared Camera

Crew


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