Assembly Instructions · 2 February 2016 James Webb Deployable Model Kickstarter Page 1 of 34

2 February 2016 James Webb Deployable Model Kickstarter

https://www.kickstarter.com/projects/2027183511/james-webb-deployable-model

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Assembly Instructions James Webb Space Telescope Mini (1/40th Scale)

Find the latest version of these instructions, videos, suggestions and related files online at http://www.mesatech.org/projects/jdtm/

Completed Model



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As-Delivered Packaged Model

Telescope Parts Bag

Part Qty Photo

Fore BSF 1

Aft BSF 1

Port/Starboard BSF 2

Upper DTA 1

Top Radiator 1

Aft Radiator ADIR

1 1

Port/Starboard Radiator 2

SMSS Upper Strut 1 1

SMSS Upper Strut 2 1

SMSS Lower Strut 2

SMA 1

SM 1

AOS 1

PMBSS 1

PMBSS Wing 2

PM CS 1

PM Wing 2



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Spacecraft Parts Bag

Part Qty Photo

Fore UPS 1

Aft UPS 1

Inboard UPS 2

MBA 2

DTA lower 1

Spacecraft bus 1

Rim Sunshield Layers

1

3



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Goodies Bag

Part Qty Photo

Keychain 5

Sandpaper 1

3mm PLA filament 1

Coasters 4



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Items helpful for assembly (not provided or mandatory)

Part Qty Photo

Wire Cutters 1

Small Zip ties 2

Rubber Mallet 1



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Telescope Assembly Instructions The telescope is made of two primary elements, the Optical Telescope Element (OTE) and the ISIM (Integrated Science Instrument Module). The supporting structure of ISIM is called the BSF (Backplane Support Fixture), which we will assemble and combine with the primary mirror of the telescope.

1. Assembling the BSF structure: a. This assembles the BSF (Backplane Support Fixture) with the radiator panels. All

parts needed for this assembly are show below. NOTE: In some packages, the Port/Starboard BSF may be already integrated with the Port/Starboard Radiators. If that is the case you can skip Steps H and I.

a. Take the Aft BSF and insert the Upper DTA (Deployable Tower Assembly) with the tube extrusion facing away from the Aft BSF. The extrusions on the Aft BSF should also be facing outboard. The long side of the Upper DTA should insert into the two holes of the Aft BSF. A light tap on the Upper DTA with a mallet sometimes helps get these pieces fully seated but please only a light tap.



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b. Press the Fore BSF onto the front (short side) of the DTA Upper

c. Rotate the assembly to its side and attach the Port BSF as shown. This fit should

be straighforward as there are three notches on the front and two on the back of the BSF that correspond to the tabs on the Port BSF. If the fit is not ideal, try switching the BSF Port with the BSF Starboard (identical pieces).



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d. Repeat the step above with the Starboard BSF. After that, you will have a fully

assembled BSF without any radiator panels integrated



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e. Here is a picture of all the radiator panels laid out in their proper position with

respect to the BSF.

f. Snap the Port Radiator onto the BSF structure by inserting your index finger into

the inside of the BSF and using your thumb to press the panel onto the outside of the structure. The extrusion of the radiator panel will fit inside cut-out of the BSF structure.



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g. Repeat step above for the starboard side.



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h. To attach the ADIR (Aft Deployable ISIM Radiator) to the aft side of the BSF, first

line up the ADIR through holes with the holes on the back of the BSF.

Once those are lined up, insert the 3mm filament through one hole.



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Next, slide the filament back so it is flush with the inside surface and cut the filament with wire cutters. If you do not have wire snips to cut the filament, you can cut a 0.5 inch piece with scissors or a knife before inserting. This will be a little more difficult to handle but will work. Repeat for both extrusions

One thing we notice is sometimes the ADIR does not stay deployed. To fix this, we have been shoving small zip-ties in-between the ADIR extrusions and the BSF structure. You can hide the zip ties with the top radiator panel or cut them off. Anything that will fit in the gap will work though. It does not need to be a zip-tie.



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i. Place the Aft Radiator on the back of the BSF. The extrusions on the panel

should fit within the rear cut-outs of the BSF. The bottom of the zip ties should be inside the BSF and covered by the Aft Radiator

j. The Top Radiator closes out the structure and should rest on top of the BSF so

that both stringers are facing downward and are nested inside the BSF structure.



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2. Secondary mirror assembly and support struts. a. All the parts needed for OTE assembly are shown below

b. Press the gold Secondary Mirror (SM) into the black Secondary Mirror Assembly

(SMA). The SM has an extrusion on the backside that fits within the hole in the SMA. Some force maybe needed but not too much. If the fit is less than good, check both surfaces and sand any discrepancies in the print.



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c. Insert the Secondary Mirror Support Structure (SMSS) lower struts into the SMA

and line up the holes. The smaller diameter sides of the lower struts fit into the each bracket on the bottom of the SMA. Also the notches on the larger diameter end should be facing inward. Next, take a piece of filament and insert it into the hole on the SMA bottom bracket such that it passes through the outer hole and into the inboard recess. Snip the excess filament to make flush.

d. To attach the SMSS lower struts to the Backplane, lay the PMBA (Primary Mirror

Backplane Assembly) on its back. The gold secondary mirror will face inwards in



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the deployed configuration so make sure that the lower struts are in the correct orientation. Place each of the lower struts into their respective bracket on the backplane and line up the holes. Then insert a piece of filament through each hole. Push the filament from the outside for best results as this hole has been drilled out and the inside hole left undrilled for a snug fit. Again trim excess to make flush.

e. The SMSS upper strut is formed by joining the two smaller SMSS upper

members. Line up the holes before inserting the filament and trimming. The SMMS Upper strut should fit inside the fork of the smaller strut. Use the correct end so the profiles of the struts match up.

f. Attach the longer member of the SMSS upper strut to the SMA. Slide a small

piece of filament through the hole so that it passes through the upper SMSS strut and trim of excess filament. If the filament is too loose, try placing a small piece of tape to capture the filament inside.

g. The upper strut can now be joined with the upper bracket joint on the PMBSS by

inserting and trimming another piece of filament. The SMSS should now be fully integrated onto the backplane. Again, if the filament is too loose, try placing a small piece of tape to capture the filament inside.



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h. Grab the AOS (Aft Optics Subsystem) and PM CS (Primary Mirror Center

Section). Press the AOS into the open hexagonal region in the center of the PM CS. The largest face of the AOS extrusion should be oriented downward.



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i. Identify the male extrusions on the PMCS and the matching female cut-outs on

the backplane. Press the PMCS extrusions into the slots on the Backplane and secure it firmly by snapping it in place.



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3. OTE and ISIM Integration. a. Identify the two rectangular male extrusions on the Fore BSF and two rectangular female cut-outs on the back of the PMBSS.



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b. Remove the Top Radiator panel from the BSF structure and press the two together in a similar fashion to the radiator panels. Make sure the Lower struts are on the bottom, next to the feet of the BSF structure.



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c. Press the PM wing segments into each wing noting the R and L on each gold segment. The R segment should be on the right when looking at the model from the back, and similarly the L segment should be on the left when looking at the model from the back.

d. The wings will snap into place by placing the lower nipple on the PMBSS onto

the cutout on the wing and then pivoting the tip of the wing into place by snapping it to be flush with the rest of the PM. The wing should rotate freely and can be adjusted vertically to align with the PM properly.



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e. You now have fully integrated OTIS (ISIM and OTE)



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Spacecraft Assembly Instructions 1. Integrate MBAs (Mid-Boom Assemblies) and DTA Lower onto the Spacecraft Bus

a. Grab both Midbooms, the spacecraft bus, and the lower DTA pieces



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b. Place each MBA base (square end) into a slot within the spacecraft bus. The

MBAs should be able to move within the slots of the Bus. Try rotating the MBA 90 degrees if the fit is less than ideal. And if it is extremely hard to insert, sand the bottom of the square part of the MBA. That is the bottom surface when printing and is sometimes wider than the rest of the part. The MBA should be able to slide with the Bus slots.



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c. Press the DTA Lower onto the top of the bus. This will capture the MBAs. Match

the cut-outs of the DTA Lower with the extrusions on the Spacecraft Bus. The cut-outs on the DTA Lower may need to be sanded down if there is too much of an interference. A nice tap with a rubber mallet sometimes does the trick too. We designed this fit to be rather snug as it will get more loose over time.

d. The Midbooms should now be deployable within the bus. The most inboard tube should be able to move within the bus and the outboard tube should be able to telescope out away from the inboard tube. When deploying the MBA try to grab the base tube first and pull it out before tugging on the outer tube. Sometimes there is much more friction between the base tube and Bus. If that is the case, try working in the base tube in and out rapidly to wear it in. Again, this will loosen over time.



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2. UPS Integration

a. Grab the Fore UPS, Aft UPS, Inboard UPS (qty2) and Spacecraft Bus. UPS stands for Unitized Pallet Structure

b. Join each UPS section (Fore and Aft) with an Inboard UPS section to make the

full Fore and Aft UPS. The male extrusion should fit within the female cut-out of the Inboard UPS.



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c. Check the male extrusion for any inconsistencies. Sometimes the top right of the

male extrusion needs to be sanded down in order to better fit within the Inboard UPS

d. Identify the notches on the each UPS. The Fore UPS is shorter than the Aft UPS.

The spreader bars are the two prongs on each UPS that allow the sunshields



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to be mounted and separated. When looking at each UPS with the spreader bars on the left, the notch will be on the top right.

3. Identify fore and aft sides of assembled bus. The fore side of the bus is flat and the aft has a slight ramp. The Fore UPS gets installed on the flat side of the bus and the Aft UPS gets installed on the ramped side.

4. Insert the non-notched side of the Fore UPS into the flat side (front) of the bus. Make

sure the UPS is vertical. The notch side should still be free from the Bus. Now slide the notch side onto the bus’ extrusions. Some (but not too much) force may be needed get the UPS to snap into the hinge.



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5. Repeat the above step with the Aft UPS and the inclined (rear) part of the bus. Each

UPS should be able to rotate from the stowed (vertical) position to the deployed (horizontal) position.



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6. You have now formed the Spacecraft Element. The MBAs should be able to telescope and both UPS should be able to rotate.

Sunshield Assembly and OTIS Integration Instructions 1. Grab the SCE, Rim, Sunshields and OTIS.



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2. The Spacecraft Element (SCE) can now be integrated with the 3 sunshield (SS) layers.

The top side of the SS is the side that has no tape reinforcement at the corners. The the orientation of the SS can be determined by placing a layer on top of the SCE and seeing which way matches best. The longer half of the SS corresponds to the rear and the shorter side corresponds to the front. The edges will line up with the spreader bars if the SS is in the proper orientations.

3. Take the first sunshield layer and gently push the punched hole over each SB until the

sunshield is fully seated on each MBA and UPS spreader bar. Layer 1 fully seated in the picture below. It should also be noted that the sunshields look their best when placed tape side down and any torn holes can be re-enforced from the underside using clear tape.



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4. Complete the same process for the 2nd and 3rd layer allowing approximately ¼” gap in

between each layer

5. To keep the SS more taught, slide the Rim down the Lower DTA. This again is a tight fit

and takes some force to push down the DTA. If it is not fitting, try flipping the Rim upside down. Worst case, some sanding maybe needed.



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6. You now have a complete SCE and sunshield assembly. Next up is the telescope

integration. Gently slide the DTA Upper of OTIS onto the DTA Lower of the SCE. Again this was designed to be a snug fit. If you need to remove the telescope, some force will be needed. Pulling up on the Upper DTA with jolts of force is the best way to separate the telescope from the bus. The model emulates all the major deployments of JWST and goes from the launch configuration to its science mode configuration.



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Any and all feedback is welcome and appreciated. We hope you enjoy our 1/40th scale model of NASA’s next great space observatory and take James Webb World Wide. Thank you.

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Assembly Instructions · 2 February 2016 James Webb Deployable Model Kickstarter Page 1 of 34