Design For Manufacture

Here’s a list of things to keep in mind when designing for our process:

  • We (and our machines) work in Imperial Units.  If you are designing in Metric you need to convert to Imperial at 1:1 scale before sending us info in order to make sure we do not introduce scale errors
  • Work in 12in increments for span/chord and you produce less waste;  save money on foam; and save on shipping if we do not need to build a custom box for 36.5 in span
  • Max taper ratio is 40%; if your tip chord/root chord is less than this the tip will get really hot and not cut well
  • Max sweep angle is 45 deg due to mechanical limits of our bow system
  • Max twist is about 10deg (we can go more but it starts to require time/materials  for test runs before we commit)
  •  Max foam thickness is 8in (we can go thicker but there is a setup charge for custom bows etc)
  • Max panel size is 4ft chord x 8ft span;  assuming constant chord; keep your top view panel geometry inside this envelope; this includes any sweep
  • Min waste for big wings results when you keep your panels below 48in;   also makes them easier to cut; and cheaper to ship
  • We can NOT start and stop tube holes, or other interior features, in the middle of the panels.    For tube holes and spar slots that are not full span, plan a panel joint at the end of feature.  This also means we do not offer pocketing operations (e.g. servo pockets)
  • EPP foam billets will yield a max usable size of 5.5in x 48in x 72in; EPS is only limited by the size of our machine since it comes in huge blocks

Current Lead Times: Up to 7 days for EPP sheet and 14 days for Quick Order Cores. We will be closed 12/30/17-1/6/18 for the New Year. Please expect some delay during that period. Dismiss