Hydroformed Reflector Time & Materials Cost Estimate

1. Hydroformed ReflectorTime & Materials Cost Estimate SKA US TDP Matt Fleming 2008-03-15 Matt Fleming

2. Purpose • This presentation is intended to estimate the cost of a hydroformed reflector system for use on a multi antenna radio telescope array. • The reflector system is composed of several parts and these parts are different for various candidate technologies. • A typical system includes the reflector surface and some support system that carries back to the elevation axis and drive attachment points. • This exercise is structured in a way that will allow other candidate reflector manufacturing processes to be compared. • It examines the process equipment, materials & tasks attempting to identify costs for each. • The hydroforming process is well known in the metal forming industry. It uses a fluid, under pressure, to form metal sheet material onto or around a mold or pattern. • Care has been taken not to disclose any information proprietary to any individual entity engaged in this business. Matt Fleming

3. Elements of Part Costs • Any manufactured device has the following cost elements that need to appear somewhere in the analysis. • Facility cost ( often covered in labor rate ) • Technology development cost. • Tooling or equipment cost ( per process ) • Setup & adjustment costs ( per batch ) • Material & Labor cost ( per part ) • Storage & trasportation costs ( per batch ) Matt Fleming

4. Surface Material So how thin can we make it ? Matt Fleming

5. Forming Matt Fleming

6. Tooling Really big guess See separate slide Costs based on educated guesses Matt Fleming

7. Mold Cost Estimateinputs are in green ratio this is the big guess Assume Improved design cool units Matt Fleming

8. Hydroformed ReflectorAssy Costs Matt Fleming