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Below is a picture of the fins used for the test fin can layup. These dimensions were obtained from our OpenRocket sim, but were not the updated shape of the fins. This was acceptable for the test fin can layup, but for the flight candidate layup the shape was different.

Flight Candidate Fin Design Process

Talk about design of phenolic slot (0.3" deep, 1/16" thick)

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Flight Candidate Fin Manufacturing Process

The fins for the flight fin can were made out of a 1/8" sheet of G10, with a phenolic leading edge made from 1/4" phenolic sheet. The fin core is G10 and had a tab cut into its leading edge, and the phenolic piece (with a slot cut into it) fits over the leading edge of the G10 fin. Below were the steps used to manufacture and assemble the fins. All of the machining was done in Gelb (Todd's shop in the basement of the Unified Lounge). 

Materials Required:

• 1/8" (0.125 in) sheet of G10 (INSERT LINK)
• 1/4" (0.250 in) sheet of phenolic (INSERT LINKhttps://www.nationwideplastics.net/phenolic-sheet/)
• 15 degree end mill (https://www.mscdirect.com/product/details/04153326)
• 1/16" cutting bit (for mill)
• West Systems epoxy (CHECK)

Part One: Waterjet G10 Fin Core (~2 hours)

*Delamination is when the layers of your composite start coming apart. This can happen if the waterjet is cutting too quickly/strongly, and especially if your composite sheet is thin (1/8" is considered pretty thin). 

1. Make a DXF drawing of your fins, keeping in mind the size of the sheet you have and the size that the waterjet can fit. Arrange the fins such that they fit close together without being too close (leave around 1/2" space) and add at least two extra fins. You'll need one extra fin to position the fins while milling the tab, and at least one other extra in case something goes wrong. 
2. Save your fin file (.dxf) onto a USB key
3. Follow the procedure for waterjetting specific to the waterjet you're using. Use a lead-in so that the waterjet doesn't start cutting right on the part, but leads into the cut (to avoid delamination*). Make sure the cutting edge is on the outside of the part, or the fins will be slightly too small. Use the "Brittle Material" and "Low Pressure" settings when making your MAKE file so that the G10 doesn't delaminate.
4. You might have to stop and start the waterjet to weight down whatever fin you're using, because if the area around your part isn't weighted, it might move around and this will ruin the shape when it gets cut out. 
5. Did you remember to make extra fins? 

Part Two: Waterjet Phenolic (~2 hours)

1. Make a DXF drawing of your phenolic leading edge. 
2. Follow the steps for waterjetting based on the waterjet you're using. Make sure to make extras, like with the G10 fin cores. Use the same settings as for the G10- even though the phenolic is thicker (1/4" inch), this will help you be sure to avoid delamination. 
3. When waterjetting, make sure to weigh down your part. Since the phenolic pieces are long and thin, there's a higher risk than with the G10 that the cut will be uneven because the part moves around as it's being cut out. 
4. After waterjetting, file

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1. down any burrs. 

Part Three: Cut 1/16" G10 Tab on Mill (~4 hours)

In this step, you're cutting the 1/16" (0.0625 in) tab on the G10, which will be epoxied into the phenolic slot. In order to leave room for the epoxy, you want to make the tab thinner than 1/16", so we chose a tab thickness of 0.058".

1. Label your fins (1, 2, 3, 4, and extras) using a Sharpie and make a table below. Since each fin has a slightly different thickness than what the manufacturer claims, you'll have to measure the average thickness of each fin and use these measurements to determine how much to cut off each side so that you have a 1/16" tab.
2. Setup is the most time-consuming part of this process. Make sure the surface that you're clamping to is wiped down and even, because any gunk stuck to it will affect the evenness of your tab. Using the spare fin, set up your fin (by clamping the two together).
3. Before you start cutting, keep in mind that you want to make around two passes, instead of just cutting each side of the tab in one go: this will help you have a more even cut. So eventually you want to get the cut to be at the Y-values shown in the table, but not in the first go. 
4. The second row of the table is how much to cut off the first side (start with less than this at first though, as detailed in the previous step). When you turn the mill on, make sure it's set to "Forward" and cutting in a clockwise direction (to the left).
5. The third row is how much to cut off the other side of the G10 to complete the tab (start with less than this at first though, as detailed in step 3). When you turn the mill on, make sure it's set to "Forward" and cutting in a clockwise direction (to the right).

*Tab thickness = 0.058"

Turn on waterjet

Select proper settings, use lead in

Use weights

Make extras

Part Two: Waterjet Phenolic

Part Three: Cut G10 Tab

Use spare fin to align G10

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