Production run order
Summary¶
The production run order sequences parts to respect coupon gate dependencies and minimise the cost of failure. Four coupons are mandatory gates — if any fail, only that coupon needs reprinting before proceeding, not downstream production parts. The sequence also respects practical logistics: the longest PCCF prints run first to establish the dimensional baseline while other coupons are still printing.
Total print time: approximately 50 hours over 6–7 days for a complete single-drone production run.
Concept¶
Why order matters¶
Parts have dependencies: - X body PCCF layers cannot be produced until Coupon 8 (T-lock fit) passes. A failed PCCF layer wastes ~1.8 hours per layer (×3 = 5.5 hours total). - Platform cannot be produced until Coupons 10 and 11 pass. A failed Platform wastes ~3.5 hours. - Arm shafts should follow X body completion so the epoxy rod-sealing sequence can run continuously.
Running coupons first, then production parts in dependency order, reduces the maximum wasted print time in any failure scenario.
Reference¶
Production sequence¶
| Step | Part | Qty | Est. time | Gate dependency |
|---|---|---|---|---|
| 1 | PETG Natural calibration coupons (1–3) | — | ~1 h | None |
| 2 | Coupon 8 — T-lock fit | 1 tab + 1 X body section | ~1 h | GATE: must pass before step 3 |
| 3 | X body PCCF layers | 3 | ~5.5 h total | Coupon 8 pass |
| 4 | X body PETG top layer | 1 | ~1.5 h | None (parallel with coupons) |
| — | Install heat-set inserts in mast boss pads | — | ~15 min | After step 4 print |
| 5a | Coupon 10 — GX12-7 chimney bore | 1 block | ~45 min | GATE: must pass before step 5c |
| 5b | Coupon 11 — battery rail slide | 1 section | ~1 h | GATE: must pass before step 5c |
| 5c | Platform | 1 | ~3.5 h | Coupons 10 + 11 pass |
| — | Remove chimney bore supports; verify connector fit + battery slide on full Platform | — | ~30 min | After step 5c |
| 6 | Backplane lattice | 1 | ~1 h | None |
| 7 | Arm tabs | 8 | ~2 h total | None |
| — | Dry-fit all tabs into T-slots; verify T-lock before continuing | — | ~15 min | After step 7 |
| 8 | Arm shafts — primary set | 4 | ~14 h total (3.5 h each) | Coupon 8b pass |
| 9 | Arm shafts — spares | 2 | ~7 h total | |
| 10 | Arm cover passive — PETG-CF | 4 | ~3 h total | Coupon 6 pass (FFP3 respirator mandatory) |
| 11 | Arm cover active — PETG | 4 | ~2 h total | Coupon 7 pass |
| 12 | ASA bumpers | 8 + 4 spares | ~1.5 h | Coupon 4 pass |
| 13 | GPS/camera bracket | 1 | ~1 h | Coupon 9 pass |
| 14 | Sensor mast + cradle | 1 set | ~1.5 h | Coupon 5 pass |
Post-production — mandatory steps before assembly¶
| Step | Action |
|---|---|
| Inspect all parts | Check for layer delamination, stringing, under-extrusion |
| Weigh all parts | Compare against mass targets in print-profiles |
| X body layers | Epoxy wipe on rod channels (thin application, correct any gaps) |
| Arm shafts | Epoxy rod channels at crossings — see airframe-integration |
| Platform | Support removal from GX12 chimney bores; verify connector and battery tests |
| Arm tabs | Dry-fit T-lock in all X body layer slots before epoxy |
Coupon 8b gate — arm shafts¶
Before printing arm shaft production run: print Coupon 8b (rod interference fit in PETG). This is separate from the T-lock Coupon 8 because the interference fit tolerance is independent of the T-slot clearance.
Procedure¶
Managing parallel runs¶
Steps 3, 4, and 6 can overlap with the later coupon prints (5a, 5b) if you have one printer: - Run step 3 (PCCF layers) on days 1–2 if printer is available overnight. - Run step 4 (PETG top) as a daytime print while you review PCCF results. - Run coupons 10 and 11 before starting Platform — not before X body.
If you have two printers: PCCF layers and arm coupons can run in parallel.
Epoxy log¶
Record every epoxy application: - Date and time - Part and location - Mass before and after (epoxy delta) - Maximum permitted deltas: shaft 1.0 g, tab 0.5 g, X body layer 1.5 g, full frame total 8.0 g
Rationale¶
Why arm shafts are step 8 rather than step 2¶
Arm shafts are long vertical prints requiring 3.5 hours each with no opportunity for early failure detection. If the T-lock coupon (step 2) reveals a variable adjustment that also affects rod channel geometry, arm shaft reprinting may be required. Starting shafts after the X body dimensional baseline is confirmed avoids this risk.
Why PCCF layers are step 3 rather than later¶
PCCF layers are the longest single batch print in the sequence. Starting them as early as possible (after Coupon 8 passes) keeps the critical path short. If a PCCF layer fails mid-print, there is time to diagnose and reprint within the production window without extending the overall schedule.
Connections¶
requires: - coupon-validation - print-profiles related: - stl-export-and-slicer-setup - airframe-integration leads_to: - stl-export-and-slicer-setup - airframe-integration