MIT Rocket Team

Preliminary Design Review

November 20, 2010

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TABLE OF CONTENTS

1 Summary of PDR Report ......................................................................................... 5 1.1 Team Summary .................................................................................................. 5 1.2 Launch Vehicle Summary .................................................................................. 5 1.3 Payload Summary .............................................................................................. 5

2 Changes Made Since Proposal ................................................................................ 6 2.1 Changes Made to Vehicle Criteria ...................................................................... 6 2.2 Changes Made to Payload Criteria .................................................................... 7 2.3 Changes Made to Activity Plan .......................................................................... 7

3 Vehicle Criteria ......................................................................................................... 8 3.1 Selection, Design, and Verification of Launch Vehicle ....................................... 8

3.1.1 Mission Statement, Requirements, and Mission Success Criteria ............... 8 3.1.2 Major Vehicle Milestone Schedule ............................................................... 9 3.1.3 Rocket Design and Subsystems .................................................................. 9 3.1.4 Subsystem Requirements and Descriptions .............................................. 10 3.1.5 Verification Plan ......................................................................................... 25 3.1.6 Risk Mitigation and Failure Modes ............................................................. 26

3.2 Recovery Subsystem ....................................................................................... 27 3.3 Mission Performance Predictions ..................................................................... 28

3.3.1 Mission Performance Criteria .................................................................... 28 3.3.2 Flight Profile Simulation ............................................................................. 29 3.3.3 Stability Predictions ................................................................................... 31

3.4 Payload Integration .......................................................................................... 32 3.4.1 Procedure .................................................................................................. 32 3.4.2 Tasking & Integration Schedule ................................................................. 35

3.5 Launch Operation Procedures ......................................................................... 35 3.5.1 Launch System and Platform ..................................................................... 35 3.5.2 Checklists and Standard Operating Procedures ........................................ 36

3.6 Safety and Environment ................................................................................... 44 3.6.1 Identification of Safety Officers .................................................................. 44 3.6.2 Analysis of Failure Modes and Mitigations................................................. 44 3.6.3 Personnel Hazards .................................................................................... 46 3.6.4 Environmental Concerns ........................................................................... 49

4 Payload Criteria ...................................................................................................... 50 4.1 Selection, Design, and Verification of Payload Experiment .............................. 50

4.1.1 Mission Statement and Success Criteria ................................................... 50 4.1.2 UAV Milestone Schedule ........................................................................... 50 4.1.3 UAV Design ............................................................................................... 50 4.1.4 Avionics Design and Subsystems .............................................................. 64 4.1.5 Electronics Design and Subsystems ......................................................... 68

4.2 Payload Creativity and Originality .................................................................... 68 4.3 Science Value .................................................................................................. 69

4.3.1 Science Payload Objectives ...................................................................... 69 4.3.2 Payload Success Criteria ........................................................................... 70

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4.3.3 Experimental Logic, Approach, and Method of Investigation ..................... 70 4.3.4 Test Measurements, Variables, and Controls ............................................ 70 4.3.5 Relevance of Expected Data ..................................................................... 72 4.3.6 Accuracy and Error Analysis ...................................................................... 73 4.3.7 Preliminary Experiment Process Procedures ............................................ 73

4.4 Safety and Environment (Payload) ................................................................... 74 4.4.1 Personnel Hazards .................................................................................... 74 4.4.2 Environmental Concerns ........................................................................... 74

5 Activity Plan ........................................................................................................... 76 5.1 Budget Plan...................................................................................................... 76 5.2 Timeline ........................................................................................................... 77 5.3 Outreach Plan .................................................................................................. 77

6 Conclusion ............................................................................................................. 80 Appendices………………………………………………………………………………..81

Table of Figures Figure 3-1: Overall Rocket .............................................................................................. 9 Figure 3-2: Tube Coupler Segment ............................................................................... 11 Figure 3-3: Nose Cone .................................................................................................. 11 Figure 3-4: Nose Cone Coupler .................................................................................... 12 Figure 3-5: Motor Centering and Retention ................................................................... 13 Figure 3-6: Recovery System Bulkhead ........................................................................ 14 Figure 3-7: Sabot Overview ........................................................................................... 15 Figure 3-8: Payload Integration Stacking ...................................................................... 15 Figure 3-9: Recovery Configuration .............................................................................. 16 Figure 3-10: Sabot Hard Point ....................................................................................... 17 Figure 3-11: MAWD Flight Computer ............................................................................ 19 Figure 3-12: ARTS2 Flight Computer ............................................................................ 20 Figure 3-13: ARTS2 Telemetry Transmitter .................................................................. 20 Figure 3-14: ARTS2 Telemetry Receiver ...................................................................... 21 Figure 3-15: ARTS GUI ................................................................................................. 22 Figure 3-16: ARTS Data Analyzer ................................................................................. 22 Figure 3-17: Power Switch ............................................................................................ 23 Figure 3-18: Avionics Package ...................................................................................... 24 Figure 3-19: Predicted CM and CP Locations ............................................................... 29 Figure 3-20: Predicted Acceleration and Velocity Profiles ............................................. 30 Figure 3-21: Simulated Altitude Profile .......................................................................... 31 Figure 3-22: Avionics assembly on plate inside tube, attached with L-brackets ............ 32 Figure 3-23: Main parachute/shock cord (green) attached to eye bolt and recovery system bulkhead (grey) ................................................................................................. 33 Figure 3-24: Tube-Tube interface .................................................................................. 34 Figure 3-25: Nose cone/upper body tube interface ....................................................... 34

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Figure 3-26: Integrated avionics assembly, main parachute, sabot and UAV assembly 34 Figure 4-1: The UAV ..................................................................................................... 51 Figure 4-2: Left Wing ..................................................................................................... 51 Figure 4-3: Right Wing .................................................................................................. 52 Figure 4-4: Building the Fuselage ................................................................................. 52 Figure 4-5: Tail Molds .................................................................................................... 53 Figure 4-6: Airfoil Comparison ....................................................................................... 56 Figure 4-7: NACA 4412 Polar ........................................................................................ 57 Figure 4-8: Vertical Tail ................................................................................................. 59 Figure 4-9: Horizontal Tail ............................................................................................. 59 Figure 4-11: Folded UAV ............................................................................................... 61 Figure 4-12: Wing Rotating Mechanism ........................................................................ 62 Figure 4-13: Wing Rotating Mechanism ........................................................................ 63 Figure 4-14: Tail Surface ............................................................................................... 64

Table of Tables

Table 3-1: Rocket Budget Summary ............................................................................. 10 Table 3-2: Hardware Specifications............................................................................... 21 Table 3-3: Risks ............................................................................................................ 26 Table 3-4: Parachute Descent Rates ............................................................................ 27 Table 3-5: Tasking and Integration Schedule ................................................................ 35 Table 3-6: Potential Failure Modes ............................................................................... 44 Table 4-1: Sensor Specifications ................................................................................... 64 Table 5-1: Funding Sources .......................................................................................... 76 Table 5-2: System Cost Summary................................................................................. 76 Table 5-3: Outreach Events .......................................................................................... 77

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1 SUMMARY OF PDR REPORT

1.1 TEAM SUMMARY

MIT Rocket Team, Massachusetts Institute of Technology Cambridge, MA Dr. Paulo Lozano Faculty Advisor

plozano@mit.edu

Andrew Wimmer Safety Officer, Rocket Owner, TRA # 9725 Level 3 awimmer@mit.edu

John Kane Local NAR Contact

kane@mit.edu

1.2 LAUNCH VEHICLE SUMMARY

The purpose of the launch vehicle is to reach an apogee of 1 mile and deploy the UAV payload after descending to an altitude of 2500 feet. Diagrams of the vehicle are provided below in the rocket section.

The carbon fiber and fiberglass airframe will be 10 feet in length, the inner diameter of the rocket tube is designed to be 6.5 inches, and the outer diameter of the fins is 16.25 inches. Furthermore, the mass of the rocket is projected to be 44.5 lbs (not including a payload mass of 7 pounds) and ballasted (in the nose cone) as necessary in order to reach an apogee of 5280 feet using a single commercial Cesaroni L1115 motor. Payload deployment will be performed at 2500 feet using two sabot halves that will be pulled out of the tube by the drogue parachute and separated using the deployable UAV wings.

1.3 PAYLOAD SUMMARY

The rocket payload will consist of a 3.75 ft long UAV that will be launched from the rocket at an altitude of roughly 2500 ft. It will fit inside the rocket by means of a folding wing, tail, and propeller. The UAV will function as a glider for the majority of its flight and will only use its motor when its velocity falls below an acceptable limit.

The UAV will fly to GPS coordinates supplied by a human operator. The UAV will not require advanced airplane or flight knowledge, which will make it useful for search and rescue type missions as well as for scientific research. The UAV will carry GPS tracking, airspeed sensors, atmospheric sensors, an accelerometer, a video capture device, and an onboard computer.

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2 CHANGES MADE SINCE PROPOSAL

2.1 CHANGES MADE TO VEHICLE CRITERIA

A number of changes have been made to the rocket design since the proposal in order to solve problems and improve the design. Many of these changes stem from a more detailed UAV design, thus enabling margin on UAV dimensions/mass to be decreased. These changes are described below by subsystem.

Airframe

• The length of the rocket was changed to 126.75 in. • The nose cone shape was changed to tangent ogive, with length of 27 in. • Fin locations will be determined by slots in the motor centering rings (the holes in

the body tube are pass-through holes rather than locating holes) • Rocket diameter decreased from 7.5” to 6.5” • Nose cone is fabricated from carbon fiber rather than fiberglass since the

antenna is wound around body tube • Body tube changed to 2 segments, affixed together with doublers (thicker

sections of a laminate in sections where shear area is needed) • Body tube-nose cone interface changed from plastic rings to doublers

Recovery

• The diameter of the main parachute was changed to 9 ft and the drogue parachute to 3 ft due to decreased rocket mass

• Standard carabineers were changed to quick links • The rocket will be recovered in two pieces rather than one: the nose cone, sabot,

and drogue parachute in one piece and the body tube and main parachute in another piece

Deployment

• The drogue parachute will be used to pull the sabot from the tube • The sabot will be restrained to the tube bulkhead using a charge released locking

mechanism (as described below) rather than shear pins

Propulsion

• The full scale test motor was selected to be Cesaroni K510 • The sub-scale test motor will be an Aerotech G80

Avionics

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• The antenna used will be a wire wrapped around the upper segment of the body tube. If this does not prove feasible, then the nose cone will be made out of fiberglass and the antenna will be mounted in it.

2.2 CHANGES MADE TO PAYLOAD CRITERIA

• The UAV tail surfaces will fold in half rather than fold backwards. This will prevent a collision with the propeller, which will be mounted at the rear of the aircraft.

• Elevators and rudders have been added in place of rotating the entire horizontal and vertical stabilizers.

• A single wing rotating mechanism will be used instead of two. This will increase the maximum chord that can be achieved and will provide a stronger connection between the wings and the fuselage.

2.3 CHANGES MADE TO ACTIVITY PLAN

• The presentation and lesion plan for both the Splash and Spark presentations have been finalized.

• Discussions with the Boston Museum of Science organizers have been started. • An event at the MIT Museum has been added to our educational outreach plan,

extending on the planned Boston Museum of Science lesson plan, but emphasizing the MIT Rocket Team’s activities. Talks with MIT Museum personnel have already been contacted.

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3 VEHICLE CRITERIA

3.1 SELECTION, DESIGN, AND VERIFICATION OF LAUNCH VEHICLE

3.1.1 MISSION STATEMENT, REQUIREMENTS, AND MISSION SUCCESS CRITERIA

Mission Statement

Use a rocket to rapidly deploy a UAV capable of completing search and rescue type missions with the use of a ground based system requiring little to no UAV flight training.

Constraints

• Follow all rules of NASA USLI 2011, including but not limited to: • Rocket apogee shall be closest to but not exceeding 5280ft. • At no time may a vehicle exceed 5600ft • Minimum science payload deployment of 2500ft • Must carry one PerfectFlight MAWD for official altitude recording • Dual deployment recovery must be used • Dual altimeters must be used for all electronic flight systems • Each altimeter must have its own battery and externally located arming switch • Recovery and payload electronics must be independent from each other • At all times the system must remain subsonic • Shear pins must be used in the deployment of both the drogue and main parachute • All components of the system must land within 2500ft of the launch site in a wind

speed of 10 mi/hr • Scientific method must be used in the collection, analysis and reporting of all data. • Electronic tracking devices must be used to transmit the location of all components

after landing • Only Commercially available, NAR/TRA certified motors may be used • Full-scale flight model must be flown prior to FRR • Students must do 100% of all work for USLI competition related projects • $5000 maximum value of rocket and science payload as it sits on the launch pad

Requirements

• Launch UAV with Rocket • Meet the needs of NASA Science Mission Directorate including:

o Gather atmospheric measurements of: Pressure, Temperature, relative humidity, solar irradiance, and ultraviolet radiation at a frequency no less than once every 5 seconds upon decent, and no less than once every minute after landing.

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o Take at least two still photographs during decent, and at least 3 after landing. All pictures must be in an orientation such that the sky is at the top of the frame.

o All data must be transmitted to ground station after completion of surface operations.

o Science payload must carry GPS tracking unit. • Successfully perform model search and rescue/reconnaissance mission

3.1.2 MAJOR VEHICLE MILESTONE SCHEDULE

The full schedule for rocket development may be found in Appendix 2. Key dates are presented below for reference:

• 9/10: Project initiation • 11/19: PDR materials due • 12/30: Scaled test launch • 1/24: CDR materials due • 2/20: Full-scale test launch • 3/21: FRR materials due • 4/14: Competition launch

3.1.3 ROCKET DESIGN AND SUBSYSTEMS

As described in the summary section, the purpose of the rocket is to reach 1 mile and deploy the UAV at an altitude of 2500 feet. This will be accomplished with a Cesaroni L1115 motor and a 10 foot long, 6.5 inch diameter airframe. The UAV will be contained within a sabot, which will be located just aft of the nosecone. The drogue parachute will be above the sabot, the main parachute below the sabot, and the avionics below the recovery system. The overall rocket can be seen in Figure 3-1.

FIGURE 3-1: OVERALL ROCKET

Furthermore, the rocket budget summary (for mass and cost) can be seen in Table 3-1.

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TABLE 3-1: ROCKET BUDGET SUMMARY

System

Mass (kg) Cost (USD)

Rocket

Propulsion 5.56 562.99

Airframe-Body 5.26 581.32

Airframe-Fairing 1.01 27.00

Avionics/Comm 0.58 1004.94

Payload Support Equipment 1.80 173.00

Recovery 2.02 480.64

SUBTOTAL 16.23 2829.89

The subsystems, which will be described in greater detail below, are: • Airframe • Recovery • Deployment • Propulsion • Avionics/Communications

3.1.4 SUBSYSTEM REQUIREMENTS AND DESCRIPTIONS

Airframe

The airframe is comprised of the following components:

• Body Tube • Nose Cone • Fins • Motor Retention System • Recovery System Bulkhead

Each of these will be described in detail below.

The body tube is a carbon fiber laminate tube of inner diameter 6.5”. The laminate is a 4-ply layup of 11 oz/sqyd woven carbon fiber fabric and Aeropoxy 2032/3665 matrix. Carbon fiber was chosen as the material for the primary structure due to its high strength-to-weight ratio, toughness, and ease of manufacture to customized shapes and dimensions. All layups for the rocket are done in-house using a custom oven and vacuum bagging equipment in the rocket team lab. For fabrication and transportation reasons, it would be difficult to make the entire tube in one segment. As a result, the body tube is split into 2 segments, with a “seam” just below the base of the sabot, as seen in Figure 3-2. The two segment lengths are 50” and 48”. The seam between the tubes is accomplished by adding doublers to each of the segments of the tubes. The inner doublers have Heli-Coil inserts so that 4x 6-32 fasteners can be used to secure the tubes together. Carbon fiber doublers were chosen as the material for the tube

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coupler due to the high strength and low relative cost compared to other methods. Furthermore, the doublers are placed (unconventionally) on the outside of the tube so as to make integration of the sabot easier and maximize the allowable dimensions of the sabot.

FIGURE 3-2: TUBE COUPLER SEGMENT

Additionally, the tube will have 2 pressure relief holes (of 0.25” diameter, unless otherwise specified) in each of the following locations:

• Just above the fins in the propulsion section • Avionics bay: the hole for the switches will double as a pressure relief hole • In the middle of the section between the avionics bay and the sabot • In the nose cone

The nose cone is a 4-ply carbon laminate, just like the body tube. The shape is a tangent ogive for manufacturing simplicity, and the length was chosen to fit the drogue parachute and maintain stability of the rocket. The length is 27 in and shape is shown in Figure 3-3.

FIGURE 3-3: NOSE CONE

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The nose cone is mounted to the body tube using 4 nylon 2-56 bolts (MMC 97263A077), which will act as shear pins. Just like in the tube coupler above, shear area is provided using doublers on both the top of the tube and the inner portion of the nose cone, as shown in Figure 3-4. Similarly, the doublers are on the outside of the tube to allow the sabot to cleanly exit the body tube. Bolts are used because they can be easily threaded into the inner doubler during integration and will fail at low loading since they are plastic.

FIGURE 3-4: NOSE CONE COUPLER

Four fins were chosen with the dimensions as shown in Appendix 3 for rocket stability reasons (see Section 3.3.3). The fins are a carbon fiber, 3/16” plywood, carbon fiber sandwich laminate to maximize stiffness with minimum mass. The fins are located in position and angle relative to the rocket using slots that are laser-cut into the motor centering rings. Oversized slits added to the body tube to allow the fins to pass through, but provide no DOF restrictions. Fabrication of the fins is as follows:

• Laminate the plywood core with a ply of carbon fiber on each face using standard plate lamination techniques (see manufacturing plan section)

• Obtain body tube with motor tube and centering rings installed • Affix fins to the centering rings using 5 minute epoxy and let cure • Apply another layer of carbon fiber across and between the fins, i.e. “Tip-to-Tip”

The motor mount will consist of a commercial 75mm motor tube and laser-cut, plywood centering rings. There will be four centering rings in total, one located at each end of the motor tube and two in the middle. The farthest forward will be made from 1/2” plywood. The farthest aft centering ring will be made from two rings of 3/16” plywood sandwiched together; the OD of the forward ring will be the ID of the body tube, and the OD of the aft ring will be the OD of the body tube. This will transfer some of the thrust load through compression of the aft centering ring, rather than through shear in the epoxy joints holding the motor mount in the body tube. The middle centering rings will be made from ½” plywood, with four slots to accept the fins, which will have ¾” tabs. One will be located near the forward edge of the fin tabs and the other near the aft edge of the fin tabs, close to the aft-most centering ring. Plywood is chosen because it is relatively

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cheap, strong, light, and able to withstand the high temperatures of the motor casing without deforming.

Motor retention will be accomplished as follows. Two 8-32 T-nuts will be mounted to the aft-most centering ring, 180° apart at a radius of roughly 2.375”. 1.5” 8-32 screws will go through two small clearance holes in the motor retention plate and screw into the T-nuts to hold the plate in place. The motor retention plate will be a piece of 1/32” steel sheet that has a hole cut in it; this hole will be made large enough for the motor’s nozzle to fit through, but small enough to keep the motor casing from falling out of the motor tube. There is a thrust ring on our 75mm hardware that prevents the motor casing from moving forward during burn.

The mounting and retention system can be seen below in Figure 3-5.

FIGURE 3-5: MOTOR CENTERING AND RETENTION

The recovery system bulkhead serves as a reaction point for forces from the payload, which come from two sources: inertial force of payload during boost, and drogue drag force between drogue parachute deployment and main parachute deployment. The bulkhead must also be removable to enable removal of the avionics bay, which sits between the motor retention bulkhead and the recovery system bulkhead. It will be affixed to the inside of the body tube using four 6-32 fasteners rather than epoxy. The bulkhead itself will have Heli-Coil inserts so that screws may be threaded into it. The body tube will have a doubler concentric with the recovery system bulkhead. The bulkhead will need to attach to both the charge released locking mechanism and the quick link to the main parachute shock cord. As a result, the bulkhead needs to have an eye bolt that is capable of transferring the loads to the bulkhead, which will be done through a threaded insert, such as MMC 94165A435. The design of the bulkhead is

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shown in Figure 3-6 and the eye bolt to be used is MMC 3067T71, which is rated to 500 lbf. Furthermore, the bulkhead will be manufactured from polycarbonate for its relative cheap price (compared to other plastic rod stock).

FIGURE 3-6: RECOVERY SYSTEM BULKHEAD

Recovery

A detailed description of the recovery process can be found in the Section 3.2.

Deployment

Deployment of the UAV and parachutes is as follows.

Initially, the stacking of the rocket above the recovery system bulkhead is as follows (as seen in Figure 3-7 and Figure 3-8):

• Payload Bulkhead attachment quick links • Charge released locking mechanism • Main parachute • Sabot base hardpoint • Sabot halves (cradling UAV) • Sabot top hardpoint • Drogue parachute quick link • Drogue parachute • Nose cone ejection charge

Note: There is a redundant igniter in the charge in the nose cone and a redundant igniter in the charge released locking mechanism.

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FIGURE 3-7: SABOT OVERVIEW

FIGURE 3-8: PAYLOAD INTEGRATION STACKING

The deployment then occurs as follows:

• Just after apogee, nose cone ejection charge fires • Nose cone separates, but remains attached to the drogue parachute • Drogue parachute deploys • Rocket descends to 2500 feet • At 2500 feet, the charge released locking mechanism fires. Mechanism to be

used is the “FruityChutes L2 Tender Descender” • The drogue parachute pulls the sabot out of the rocket tube • As the sabot leaves the tube, the spring-loaded UAV wings push the sabot

halves apart • The sabot pulls the main parachute bag out behind it • Main parachute deploys and remains attached to the main body tube

After deployment, the rocket will fall to the ground in two sections, as shown in Figure 3-9:

• Sabot and nose cone, which are attached to the drogue parachute via the upper hardpoint and a shock cord

• Main body tube, which is attached to the main parachute via the recovery system bulkhead and a shock cord

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FIGURE 3-9: RECOVERY CONFIGURATION

Deployment into two pieces (rather than one) is performed in order to minimize the chance of contact between the sabot/UAV and the body tube after separation. This will enable the drogue parachute to pull the UAV/sabot away from the rocket to allow clean separation and minimize the chances of entanglement.

As described above, the UAV is encased within the two sabot halves, which are made of foam and laminated in a ply of fiberglass so as to maintain shape. Force will be transferred between the hardpoints using a 4x 10-24 nylon threaded rods, which will mount to the upper and lower hardpoints using clearance holes and nuts. Finally, plastic hardpoints are glued to the upper and lower ends of the sabot halves. These hardpoints enable recovery and deployment system fixtures to be attached to the sabot. One of these hardpoint sets is shown in Figure 3-10. As can be seen below, the hardpoint halves overlap to ensure force transfer between halves when in tension. Adhesive is applied as shown in the figure. An eye bolt is threaded into the lower hardpoint half, which serves as the attachment points for:

• Lower hardpoint: the charge released locking mechanism • Upper hardpoint: the drogue parachute and upper shock cord (attaches to nose

cone)

It should be noted that the upper hardpoint will require eye bolts in both hard point halves due to ensure both sabot halves remain attached to the drogue parachute.

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FIGURE 3-10: SABOT HARD POINT

Propulsion

The rocket will be powered by a Cesaroni L1115 solid rocket motor. This motor was chosen because it is commercially available and does not require any modifications in order to reach the flight altitude requirement of 5280 feet based off the mass estimates available this early in the design process. The motor is actually more powerful than required given the current mass estimates, but this will ensure that even with mass creep over multiple design iterations, the rocket mass can be optimized with ballast weight to come as close to 5280 feet as the models can predict.

The Cesaroni L1115 is also reloadable and relatively inexpensive compared to its Aerotech counterparts. It does not require extensive ground support equipment compared to hybrid motors, which were originally considered for propulsion. The L1115 is 75mm in diameter, 24.5 inches in length, and has a total impulse of 4908 Newton-seconds over a 4.49 second burn time.

For the full-scale test, the Cesaroni K510 solid rocket motor will be used. The K510 has enough power to launch the full system up to an altitude of 2000 feet and still has the same diameter as the L1115, so minimal changes will have to be made to the motor housing section for the full scale test launch. The K510 is 75mm in diameter, 13.8 inches long, and provides 2486 Newton-seconds of thrust over a 4.84 second burn time

Avionics/Communications

The purpose of the rocket avionics is to control parachute deployment while collecting rocket flight data and relaying it to the ground station.

The rocket avionics system is comprised of two flight computers (miniAlt/WD and ARTS2) and an ARTS2 transmitter. The miniAlt/WD flight computer serves as a backup altimeter that measures the rockets altitude during launch and stores in on the computer board and will fire a redundant igniter for the recovery charge after the ARTS is

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programmed to. This data can be retrieved after rocket recovery where the miniAlt/WD flight computer is connected to the ground station computer via a miniAlt/WD to PC Connect Data Transfer Kit. The ARTS2 flight computer handles primary parachute deployment as well as determining the rocket state variables and flight states. The ARTS2 Transmitter transmits the data from the ARTS2 to the ground station receiver.

Rocket Flight data includes:

• State Variables: o Altitude o Maximum Altitude o Velocity o Acceleration

• Flight State: o On Pad o Thrust o Coast o Apogee o Descent o Drogue parachute Deployment o Main parachute Deployment

Power Supply

Three 9 volt batteries will provide power for the flight computers and transmitters. One of the batteries will be dedicated towards powering the miniAlt/WD while the other two will power the ARTS2 flight computer and telemetry system to create a power source redundancy in case one was to fail. On the ARTS2 board one battery powers the two systems while the other powers the igniters. They will be located inside the removable rocket avionics section of the rocket, alongside the rest of the avionics system.

Hardware Description

MiniAlt/WD Logging Dual Event Altimeter (PerfectFlite)

This flight computer measures the rocket’s altitude by sampling the surrounding air pressure relative to the ground level pressure. The altitude above the launch platform is calculated every 50 milliseconds. After launch, the device continuously collects data until landing. Altitude readings are stored in nonvolatile memory and can be downloaded to a computer through a serial data I/O connector. The miniAlt/WD has two channels for parachute deployment; one for the main parachute and the other for drogue parachute.

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FIGURE 3-11: MAWD FLIGHT COMPUTER

Altimeter Recording and Telemetry System (ARTS2 Flight Computer) (Ozark Aerospace)

This flight computer calculates the rockets altitude by sampling the surrounding air pressure relative to the ground level pressure and measuring the rockets acceleration. The rate at which the altitude above the launch platform is calculated is adjustable and will be set at 100 samples per second with an overall recording time of 5.4minutes. Altitude readings are sent to the ground station via the ARTS2 telemetry transmitter. Also the altitude and other flight data are stored in nonvolatile memory to be downloaded to a computer through a serial data I/O connector. The ARTS2 has two channels for parachute deployment; one for the main parachute and the other for drogue parachute.

1. Terminal Connector 2. GPS Connector 3. Programming header 4. Battery Configuration 5. Main Battery Connection 6. Power Switch Connector 7. 9V Pyro Battery Connection 8. Option Switches 9. Output Channel Terminals. Channel 1 Apogee, Channel 2 Main.

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FIGURE 3-12: ARTS2 FLIGHT COMPUTER

ARTS2 Telemetry Transmitter (Ozark Aerospace)

• 100mW 900MHz spread spectrum transmitter • Integrated wire antenna on the board is connect to a larger antenna on the rocket • Works with the ARTS-TT2-W and ARTS-TT2-RPSMA • ARTS flight computer gets connected directly to the transmitter board • Transmits real time flight data to the ARTS telemetry receiver

FIGURE 3-13: ARTS2 TELEMETRY TRANSMITTER

ARTS2 Telemetry Receiver (Ozark Aerospace)

• Receives telemetry from the ARTS2 transmitter and sends it to the computer • Connect to the ground station computer via a serial cable

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FIGURE 3-14: ARTS2 TELEMETRY RECEIVER

TABLE 3-2: HARDWARE SPECIFICATIONS

Hardware Operating Voltage

Minimum Current

Dimensions Weight Altitude

Accuracy Operating

Temperature Maximum Altitude

MiniAlt/WD 6-10 volts 10

milliamps

0.90”W, 3.00”L, 0.75”T

20 grams

+/- .5% 0C to 70C

25,000

feet

ARTS2 9-25 volts 1.40"W, 3.75"L, 0.75"T

~20 grams

100,000

feet

ARTS2 Transmitter

6.8 -25 volts

~2.50"W, ~7.50"L, ~1.50"T

~200 grams

100,000

feet

Switches

The single power switch is a push-on/push-off switch that delivers power to all of the avionics components when on. The three arming switches are RBF pull-pin switches.

Software

Telemetry software:

Displays flight data in real time using text, 2-D, and 3-D graphical user interfaces.

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FIGURE 3-15: ARTS GUI

ARTS Software V1.61 (Data Analyzer):

Used in analyzing the data collected by the ARTS2 and also configuring parachute deployment and sample rate settings.

FIGURE 3-16: ARTS DATA ANALYZER

Parachute Deployment

Both the ARTS2 and the miniAlt/WD are programmed to deploy the drogue parachute at apogee, while the main parachute and the UAV are set to deploy after apogee is reached at an altitude of 2500 feet. This creates system redundancy in case one of the flight computers fails.

Transmission from Rocket to Ground Station

Since the carbon fiber material of the rocket body tube disrupts any RF signals the wire on the ARTS2 transmitter will be extended out of the avionics bay. There are two possible options for doing this.

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1) The 14 gauge copper wire is connected to the transmitter antenna via a binding post. It then extends from the avionics bay and warps around the upper section of the rocket body. Each loop of the helix is spaced 33 centimeters apart to prevent destructive interference. Kapton tape is placed above and below the wire to prevent contact with the carbon fiber.

2) The ARTS2 transmitter antenna is extended directly to the fiberglass nose cone and connects to a 25 inch long (4 millimeter in diameter) RF antenna. It should be noted that the nose cone is currently carbon fiber, so it would need to be changed to fiberglass if this modification is made.

Arming and Power Switches

FIGURE 3-17: POWER SWITCH

The avionics bay contains two plunger type switches that connect the power to the miniAlt/WD flight computer and the ARTS2 altimeter telemetry system and two switches with Remove Before Flight [RBF] pins to arm the flight computers. The power and arming switches are used in order to prevent premature firing of ejection charges and power usage before the rocket is on the launch pad.

Mounting/Placement

Placed in the avionics bay, which is in the lower segment of the rocket as described below. The flight computers will be mounted in such as way so that their pressure and acceleration readings are not disturbed. This means that the barometer on both the ARTS2 and miniAtl/WD would have to have at least a 1 centimeter clearance from any closest surface parallel to it. Also, the ARTS2 will be mounted with its length parallel to the rocket’s length in order for the accelerometer to record proper positive values.

The avionics will be mounted into an avionics integration tube, which is shown below in Figure 3-18.

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FIGURE 3-18: AVIONICS PACKAGE

As can be seen in the figure, the boards and battery are mounted to a plate, which will be mounted vertically in the rocket frame. A series of L brackets will be used to mount this vertical avionics plate to the avionics tube, which can be integrated with the rocket in a preassembled form. Additionally an ELT will be mounted to the side of the avionics assembly. The hole in the top of the avionics package is for wires to reach into the upper portion of the rocket (a similar hole exists in the recovery system bulkhead). The switches on the bottom image are used to arm each of the following just before launch:

• ARTS2/ARTS2 Transmitter Power Switch • MAWD Power Switch • ARTS2 Arming Switch • MAWD Arming Switch

The power switch will be push-on/push-off. The arming switches will be armed by removing Remove Before Flight [RBF] tags. The switches will also have the capability of being flipped without reinsertion of the RBF tag.

The bottom of the avionics tube will be glued permanently to the phenolic tube packaging shell. The boards and batteries can be mounted to the avionics plate, which is mounted to the top plate using 4x 4-40 fasteners. After insertion into the tube, four

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additional 4-40 fasteners are bolted from the bottom plate into the bottom L brackets, the holes of which are threaded. After this is assembled, the whole avionics package may be inserted into the rocket as described in the payload integration plan. This design was chosen to make the avionics assembly as modular as possible, while still maintaining access just before flight and low mass/cost of the assembly.

3.1.5 VERIFICATION PLAN

The team’s first priority will be to perform qualification testing on the structural components of the rocket. The tests to be performed are as follows:

• The body tube will be tested using a crush test in the axial direction and bending test in the lateral direction. It will be tested with a variable mass, such as sand, to determine the stiffness and failure force.

• A crush test will also be performed between two tubes to verify the strength of the tube coupler.

• The bulkheads and their attachment to the body tube will be tested with a pull test, in which the tube will be fixed and variable mass will be used to determine pullout force.

• The fins will also be tested using a series of pull/push tests (also using a variable mass and gravity) in order to test the fin strength in each of the 3 orthogonal directions.

In addition to structural testing, several deployment and recovery tests will need to be performed:

• Deployment altitude will be verified using barometric testing. The team has constructed a small vacuum chamber, which is capable of roughly simulating ambient pressure. As a result, the avionics package will be placed into the vacuum chamber to ensure that it sends charge ignition commands at the right times.

• In order to verify the failure force of the shear pins, a representative tube will be used with a representative nose cone, with the open side of the tube covered. The shear pins are mounted into the relevant brackets in flight orientation. The black powder charge will be ignited at the closed end to validate the mass of black powder to be used.

• UAV deployment will also require testing, which can be performed in a couple of phases: (1) the force of the drogue parachute on the sabot can be simulated to ensure that the sabot separates from the tube and the UAV deploys and (2) integrated deployment tests from a balloon platform. This test will be described further in Section 4.3.4.

A series of avionics tests will also be performed. A summary of the tests is provided below. Greater detail can be found in Section 4.3.4.

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• The emergency locator beacons (transmitters and receiver) operation will be checked, by searching for the beacons in a representative location.

• Each computer will also be checked to see if they downlink properly to the ground station. This will be performed on the ground in a field and then on a balloon platform using a representative ground station and rocket.

Finally, these tests will culminate in a representative scaled test launch, which will verify functionality of all systems, including the UAV.

3.1.6 RISK MITIGATION AND FAILURE MODES

TABLE 3-3: RISKS

Risk Likelihood Effect on Project

Risk Reduction Plan

Scale test model flight failure

Medium Low Ensure model is stable and meets

safety codes.

Full-Scale Test Flight Failure

Medium-High

High

Ensure appropriate simulations and testing are done before flight. Do not fly with any outstanding technical or safety issues. Leave time in schedule for a re-flight and construction of a new vehicle.

Team member suffering major

accident or illness

Medium Low

Ensure team members and mentors can suitably make up for the

unavailability of a team member due to illness.

Loss of support by any critical personnel,

sponsors or organizations

High High

Ensure all supporting organizations understand their importance to the

project and plan ahead incase problems arise. Cross train team members to be able to step in for

others.

Vehicle Damage from

transportation or other causes prior

to launch

Medium High

Ensure vehicle is packed securely and packaging and vehicle are rugged

enough to handle transportation. Carry spares for parts that are known to be

easily breakable.

Unforeseen regulatory

Low Medium Ensure that knowledge of regulations is kept up to date to know of any

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problems impending problems.

Late delivery of vehicle

components Medium Medium

Ensure components are available and ordered early enough to ensure proper

arrival time

Payload components are not ready in time

High High Plan ahead and keep on schedule to ensure delivery of tested UAV in time

for rocket flight testing

Vehicle components are not ready in time

Medium High Plan ahead and keep on schedule. Make simplifications if necessary.

3.2 RECOVERY SUBSYSTEM

When the drogue parachute is deployed at apogee, it will need to support a total system mass of 23 kg. A 3ft diameter parachute will be used to achieve a descent rate of 64 ft/s.

Once an altitude of 2500 ft AGL is reached, the tether securing the sabot inside the rocket will release, allowing the drogue parachute to pull the sabot and the main parachute out of the rocket. At this point, the rocket body will separate from the sabot/nose/drogue section and free fall as the main parachute deploys. This will allow for a considerable gap between the rocket body and the sabot, decreasing the risk of the deployed UAV colliding with the rocket or becoming entangled in the main parachute.

With the UAV deployed and the sabot separated from the rocket body, the remaining structure has a mass of 15 kg. With a 9ft diameter parachute, a final descent rate of 18 ft/s can be achieved. Under the 3ft parachute, the nose cone and sabot will have a final descent rate of 22 ft/s.

TABLE 3-4: PARACHUTE DESCENT RATES

Final Descent Rate System Under Drogue 64 ft/s Nose/Sabot Final Descent Rate

22 ft/s

Rocket Body Under Main 18 ft/s

The drogue parachute and nose cone are directly connected to the sabot. This assembly is initially connected to the recovery system bulkhead via the explosive tether.

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The main parachute is also secured directly to the recovery system bulkhead (not by the tether). Its deployment is constrained by the sabot.

The calculations for the amount of black powder required to successfully separate the nose cone from the body tube can be found below.

The charge release mechanism will contain 0.2 grams of black powder. This number is recommended by the manufacturer.1

The drogue deployment charge must provide ample force to break the shear pins, accelerate the nose cone away from the rocket body, and accelerate the drogue parachute out of the nose cone. Four 2-56 nylon screws (MMC 94735A177) will be used a shear pins to retain the nose cone. Nylon 6/6 has a shear strength of 10ksi.2 With this, the maximum shear force can then be calculated by the following equation:

� = � ⋅ �,

where A is the cross-sectional area of the bolt, and τ is the shear strength. For a 2-56 screw, the minimum pitch diameter is 0.0717 in.3 This leads to a shear force of 40 lbf. With four pins, the charge will have to provide a minimum force of 120 lbf. Adding 25% margin, the charge will need to provide a total force of 150 lbf. This leads to a required black powder mass of 2.1 g.4

3.3 MISSION PERFORMANCE PREDICTIONS

3.3.1 MISSION PERFORMANCE CRITERIA

In order for this mission to be considered a success, the following events must occur:

• Achieve an altitude as close to 5280 feet (1 mile) as possible. (It is preferable to undershoot the target, as the flight score penalty for overshooting is twice as great.)

• Eject nose cone and deploy drogue parachute at apogee • Deploy UAV and main parachute at an altitude of 2500 ft • The UAV must unfold its wings and start the primary science mission objective. • Land safely (intact and reusable with no necessary repairs) on the ground.

1 Tender Descender User’s Guide, http://fruitychutes.com/Recovery_Tether_manual.pdf 2 http://www.aptllc.net/datasheets/Nylon66.pdf 3 http://www.engineersedge.com/screw_threads_chart.htm 4 Black Powder Pressure-Force Calculator: http://www.info-central.org/files/303-Pressure_Force_Calculator_Ver2.xls

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3.3.2 FLIGHT PROFILE SIMULATION

For the Preliminary Design Review flight profile simulations, RockSim was used. A model of the rocket was built in RockSim, and the mass was verified against the Solidworks model. Parachute descent rates were verified against the MATLAB parachute sizing model. The RockSim model agreed with the Solidworks model mass to within 0.1 pounds and with the MATLAB model descent rates to within 3 feet per second. Figure 3-19 shows the RockSim model.

FIGURE 3-19: PREDICTED CM AND CP LOCATIONS

A battery of simulations was run, taking into account the approximate location and altitude of the launch site and average temperature, pressure, and humidity conditions. It was known that the Cesaroni L1115 would be more powerful than necessary and propel the rocket higher than the target altitude. With no added ballast or winds, the rocket flew over 800 feet above the target altitude. This was expected and desired, especially considering the mass margin of the payload and other components, the masses of which have only been measured up to this point. Initially, the RockSim model had a mass of 19.75 kg and an initial stability margin of 2.26, which is comfortably stable but makes the rocket susceptible to angling toward gusting winds.

Groups of ten simulations were run to find an optimal mass of the ballast that needed to be added. Each simulation had variable light winds (3-7 mph), and the ballast mass and launch rail angle were varied until the desired apogee and landing range distance were achieved. The optimal value for the ballast weight added to the bottom motor bulkhead mount is 3.65kg, giving the rocket a total wet mass of 23.4 kg, and the optimal launch angle is 2 degrees. This gives an average altitude over 10 simulations of 5275 feet (maximum 5296 feet, minimum 5243 feet) and a distance at landing of no more than 500 feet from the launch location, with an average distance of 100 feet.

At t = 0, the Cesaroni L1115 is ignited. Burnout occurs at 4.49s, and apogee occurs at approximately 19.4 seconds. At this time, the first charge is ignited to eject the nosecone and deploy the drogue chute, which pulls the sabot out of the rocket. At an altitude of 2500 feet, the second charge is ignited. This charge releases the UAV from the sabot, separates the nosecone, drogue chute, and sabot from the rest of the rocket body tube, and deploys the main parachute.

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Figure 3-20 shows the acceleration and velocity of the rocket during the first 30 seconds of flight (the remaining flight time was omitted for clarity). The maximum speed occurs near burnout, and does not exceed Mach 0.5. The maximum predicted acceleration occurs at the parachute deployment, as expected. While the magnitude of the maximum acceleration is high compared to what was expected, this is still within the range that the carbon fiber structure of the rocket can stand. An initial concern was that the parachute cords could rip the body tube apart during high-speed deployment. Future modeling will try to reconcile the nearly instantaneous parachute deployment featured in RockSim and the expected unraveling time of the chute to prevent such high accelerations in simulations.

FIGURE 3-20: PREDICTED ACCELERATION AND VELOCITY PROFILES

Figure 3-21 shows the simulated altitude profile of the rocket. Burnout and apogee are shown with red and blue dotted lines, respectively, and the main parachute deployment can be seen as the kink in the altitude line near 50 s.

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FIGURE 3-21: SIMULATED ALTITUDE PROFILE

Future flight profile modeling will more accurately define the launch conditions, including launch pad altitude, predicted weather conditions (relative humidity, average wind speed, etc.), and competition settings. Immediately before the flight, these conditions will be taken into account and the mass of the ballast will be adjusted according to on-site simulations to achieve the predicted altitude given the very best initial conditions simulations the team can generate.

3.3.3 STABILITY PREDICTIONS

The initial static margin of the rocket with all the ballast placed at the bottom of the bottom motor bulkhead is 1.17. This is an appropriate static margin that makes the rocket less susceptible to wind gusts during flight that would cause an overstable rocket to tilt into the wind, but not so close to unstable that unexpected changes in the masses of some of the components would jeopardize the overall stability. During flight, the static

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margin will increase as propellant is burned and the center of mass moves toward the nose of the rocket. The static margin at burnout is 1.64.

If 0.8 kg of ballast mass is moved from the bottom bulkhead to the sabot, then the initial static margin is 1.56. At burnout, the static margin is 2.08. This does not significantly change the maximum altitude of the rocket.

3.4 PAYLOAD INTEGRATION

3.4.1 PROCEDURE

1) Integrate Avionics Bay a) Integrate avionics boards and ELT onto avionics plate b) Integrate 3 New Batteries c) Test electronics (turn on) d) Attach avionics plate onto top cap with L-brackets and 5/8” 4-40 screws e) Attach avionics plate onto bottom cap with L-brackets and 1/2” 4-40 screws f) Slide assembly into tube g) Slide recovery system bulkhead into rocket and secure with screws h) Check all connections i) Check pressure holes

FIGURE 3-22: AVIONICS ASSEMBLY ON PLATE INSIDE TUBE, ATTACHED WITH L-BRACKETS

2) Make Black Powder Ejection Charges a) Safety Officer will oversee this step b) Connect to avionics

3) Recovery a) Fold drogue parachute (use talcum powder) b) Integrate drogue parachute and parachute protector

i) Attach to upper sabot hardpoint with quick link

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c) If main parachute is not already properly folded in the parachute bag, fold main parachute (use talcum powder)

d) Integrate main parachute and parachute protector (Figure 3-20) i) Attach main shock cord to payload eye bolt with quick link ii) Attach main parachute to shock cord with quick link iii) Attach parachute bag to lower sabot hardpoint

e) Attach charge release locking mechanism to payload eye bolt i) Connect leads to avionics ii) Attach to lower sabot hardpoint

f) Nose Cone i) Attach secondary shock cord between nose cone and sabot with quick links ii) Install ELT

g) Nose Cone, Drogue, and Sabot should not be attached to main shock cord h) Check all quick links (tighten with wrench)

FIGURE 3-23: MAIN PARACHUTE/SHOCK CORD (GREEN) ATTACHED TO EYE BOLT AND RECOVERY SYSTEM BULKHEAD (GREY)

4) Integrate antenna a) Antenna is pre-attached to main body b) Connect the antenna (14 gauge insulated copper wire) to the avionics using a

binding post connection 5) Integrate rocket body with sabot/UAV assembly

a) Attach two rocket body segments together (Figure 3-21) i) Thread four 6-32 ½’’ bolts through doublers

b) Slide sabot (with UAV) in routing the wires from the avionics assembly through the raceway

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FIGURE 3-24: TUBE-TUBE INTERFACE

6) Integrate Nose Cone a) Slide into upper body tube (Figure 3-24)

FIGURE 3-25: NOSE CONE/UPPER BODY TUBE INTERFACE

FIGURE 3-26: INTEGRATED AVIONICS ASSEMBLY, MAIN PARACHUTE, SABOT AND UAV ASSEMBLY

Sabot Upper Body Tube Segment

Lower Body Tube Segment

Upper Doubler

Lower Doubler

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3.4.2 TASKING & INTEGRATION SCHEDULE

TABLE 3-5: TASKING AND INTEGRATION SCHEDULE

Overall Task Number of People* Time Integrate avionics

assembly 3 15 minutes

Assemble UAV 2 5 minutes Integrate main parachute 2 15 minutes Integrate UAV assembly

with recovery system 3 5 minutes

Integrate drogue parachute

2 5 minutes

Integrate nose cone 2 2 minutes Integrate motor 2 4 minutes

Total time: Approximately 60 minutes

• This includes one person with the checklist who will be supervising

3.5 LAUNCH OPERATION PROCEDURES

3.5.1 LAUNCH SYSTEM AND PLATFORM

Launch Pad

We will be using a Vaughn Brother’s Rocketry “High Power Launch Pad” with a 10ft extruded aluminum T-slot rail.

Features:

• 200lb capacity • Folds for easy transportation • Holes in feet for staking the pad to the ground • 12inch x 0.1inch thick steel blast deflector • Accepts launch rods 1/4”- 3/4” and launch rails (with adapter)

Electrical Launch System (ELS)

The ELS will be powered by a battery(s), have a safety interlock in series with the launch switch, will use a launch switch that returns to the “off” position when released, and have leads long enough for a safe launching distance (at least 300ft). A specific ELS has not been selected. We already have access to some ELS’s, or we may

36

purchase one of many available commercial ELS’s. Custom ELS’s are also being investigated.

3.5.2 CHECKLISTS AND STANDARD OPERATING PROCEDURES

Caution Statement

Recall the Hazards Recognition Briefing. Always wear proper clothing and safety gear. Always review procedures and relevant MSDS before commencing potentially hazardous work. Always ask a knowledgeable member of the team if unsure about equipment, tools, procedures, material handling, and/or other concerns. Be cognizant of your and others’ actions. Keep work station as clutter-free as possible.

Equipment Packing Checklist:

1. Support Equipment and Tools a. Safety Gear

i. Goggles ii. Rubber Gloves iii. Leather/Work Gloves iv. Face Masks v. All Safety Documents and References

b. Furniture i. Tent (1x) ii. Tables (2x) iii. Chairs (6x) iv. Rocket assembly benches

c. Generator i. Gas ii. Power Strip(s) (3x) iii. Extension Cord(s) (3x)

d. Tools i. Corded Drill ii. Cordless Drill

1. Cordless Drill Batteries 2. Charger

iii. Drill Bit Index(s) iv. Wrench Set v. Pliers vi. Screwdriver Set vii. Hex Keys Set viii. Files

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ix. Sandpaper x. Knives xi. Flashlight xii. Soldering Iron

1. Solder 2. Solder Wick 3. Sponge

xiii. Wire Cutter/Stripper(s) xiv. Extra Wire (Black and Red) xv. Pocket Scale

e. Adhesive i. 5-minute Epoxy (2 part) ii. CA and Accelerant iii. Aeropoxy (2 part) iv. Epoxy Mixing Cups v. Popsicle Sticks vi. Foam (2-part) vii. Foam (solid)

f. Other supplies i. Tape

1. Duct Tape 2. Scotch Tape 3. Vacuum Tape 4. Electrical Tape 5. Masking Tape 6. Gaffer’s Tape

ii. Trash Bags iii. UAV Camera Dome Cleaner iv. Isopropyl Alcohol (general clean up) v. Water Bottle vi. Camera Lens Cleaning Supplies vii. Paper Towels viii. Wipes ix. Spare Hardware x. Lithium/Silicon Grease (for building reload; other) xi. Zip-ties xii. Talcum Powder (for parachutes)

2. Ground Station a. Antennas

i. Rocket (1)

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ii. UAV (3) iii. Antenna Mounts

b. Emergency Locator Transponder (ELT) (UAV and Rocket) (3x) c. Emergency Locator Receiver d. UAV Main “Pilot” Computer e. UAV Secondary Computer f. Rocket Ground Station Computer g. UAV Manual R/C Controller h. Monitors i. Power Adapters for all Computers j. Mice (3x) k. Cables

i. Antennas ii. Monitors iii. Other

l. Miniature Weather Station (wind speed/direction, temperature) 3. Launching Equipment

a. Launch Pad b. Launch Rail c. Stakes for Pad d. Angle Measuring Tool e. Electronic Launch System (ELS)

i. Battery ii. Battery Charger iii. Controller iv. Leads

4. Rocket a. Body

i. Lower Tube Section ii. Upper Tube Section iii. Nose Cone iv. Ballast v. Shear Pins (10x)

b. Recovery i. Parachutes

1. Drogue (2x) 2. Main (2x) 3. Nomex Parachute Protectors (3x)

ii. Shock Cord iii. Ejection Charges

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1. Black Powder 2. Charge Holders (4x) 3. Igniters (4x)

iv. Charge Released Locking Mechanism (2x) v. Quick links (10x)

c. Motor i. Casing ii. Reload (2x) iii. Retention

1. Retention Plate 2. Retention Hardware

d. Avionics i. Avionics Bay ii. Altimeters

1. ARTS2 (1x) 2. ARTS2 Transmitter Board (1x) 3. MAWD (1x)

iii. Antenna (attached to outside of rocket body) iv. 9V Batteries (10x) v. ELTs (one in Bay, one in nose cone) (3x) vi. Hardware

1. 4-40x1” bolts (10x) 2. 4-40 locknuts (6x)

5. UAV a. UAV b. Motor (2x) c. UAV Propeller (3x) d. UAV Lithium Polymer Batteries (2x) and Spare Batteries (3x) e. Lithium Polymer Battery Charger/Balancer f. Spare Servos (3x) g. Spare Control Linkages h. Sabot i. Avionics

i. Flight Computer ii. Back up Sensor Logging Board iii. Sensors iv. Flight Digital Still Camera v. Video Board and Video Camera vi. Manual Control Receiver (Back Up: 72MHz) vii. Antennas (72MHz, 900MHz, 2.4GHz)

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viii. ELT 6. Miscellaneous

a. Digital Camera b. Video Camera c. Extra Batteries d. Binoculars e. Two-Way Radios f. Two-Way Radio Chargers

Pre-Flight Checklists:

1. Ground Station a. Furniture Set Up b. Generator

i. Full Tank ii. Extra Gas iii. Connect Extension Cord(s)/Power Strip(s)

c. Computers i. Set Up ii. Plug in Power Adapters iii. Mice iv. Set Up Monitors v. Power Up

d. Antennas i. Mount and Set Up

1. 2.4GHz 2. 900MHz

ii. Connect to Computers e. Set Up ELT Receivers

i. Test on each of 3 channels 2. UAV

a. Mechanical i. Inspect Fuselage (follow detailed checklist)

1. Internal Structure 2. External Structure 3. All Electronics/Avionics Mounts 4. Motor Mounted Securely 5. Kevlar Skid Plate

ii. Inspect Wing and Wing Folding Mechanism iii. Test Wing Folding Mechanism

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1. Fold and let Unfold at least twice 2. Adjust as necessary

iv. Inspect all Hinges v. Test All Folding Hinges

1. Fold and let Unfold 2. Adjust as necessary

vi. Unfold Everything vii. Inspect All Control Surfaces

1. All should be free and clear to rotate 2. Inspect and Move All Hinges 3. Inspect Control Linkages and Servos

viii. Inspect Camera Dome 1. Clean Dome if necessary 2. Check Connection to Fuselage 3. Check Camera Mount

ix. Inspect UV Sensor Window 1. Clean if necessary

b. Power Systems i. Inspect Motor ii. Check if Propeller Secure iii. Give Motor a Test Spin (by hand) iv. Inspect Motor Controller v. Make sure all electronics are Switched Off vi. Connect and Secure Charged Lithium Polymer Batteries

c. Avionics i. Install Flight Computer ii. Install Back up Sensor Logging Board iii. Install Video Board and Video Camera iv. Install Digital Camera v. Install Manual Control 72MHz Receiver (Back Up) vi. Inspect All Sensors vii. Install ELT viii. Connect Everything

d. Communication/Controls i. All servos connected to proper channels ii. All Avionics Connected iii. Power On iv. Test All Control Surfaces (using standard/manual R/C 72MHz

transmitter) 1. Trim

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2. Actuate one direction 3. Actuate other direction

v. Test Motor (using standard/manual R/C 72MHz transmitter) 1. Clear objects/people from the plane of the propeller 2. Throttle Up 3. Throttle Down

vi. Power Motor/Motor Controller Off vii. Test Flight Computer

1. Communicating with Ground Station viii. Test Data Feeds (turn UAV avionics on)

1. Temperature 2. Humidity 3. Solar Irradiation 4. UV Irradiation 5. Pressure

ix. Test IMU/GPS 1. Transmitting Telemetry

x. Test Autopilot (Make sure control surfaces respond correctly) 1. Pitch UAV Up 2. Pitch UAV Down 3. Yaw UAV Right 4. Yaw UAV Left 5. Roll UAV Left 6. Roll UAV Right

xi. Test Data Logging 1. Digital Camera Still Shot Recorder 2. Back Up Sensor Data Logging

xii. Test Video Feed 1. Receiving Video

xiii. Test ELT 1. Receiving ELT signal

xiv. Power Up Motor/Motor Controller xv. Flight Test with Manual R/C Control (no autopilot)

1. Receiving All Data 2. Proper Control Responses

xvi. Ground Test of Point-and-Click Control (with autopilot) 1. Receiving All Data 2. Proper Control Responses

xvii. Aerial Test of Point-and-Click Control 1. Trim control surfaces before flight

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2. Back Up with Manual R/C Control e. Switch out Lithium Polymer Batteries f. Final Overall Inspection g. Install UAV into Sabot

3. Rocket a. Lay-out rocket sections in order b. Check Body Antenna c. Install Ballast into appropriate sections of sabot and body tube d. Refer to Payload Integration Plan

i. Follow, then continue with this checklist e. Install all shear pins f. Prepare Motor Reload

i. Safety Officer will oversee this step g. Slide motor casing into rocket h. Screw on motor retention i. Make sure the tube-tube and tube-nose cone interfaces are secure j. Inspect rail guides k. Do a pre-launch briefing

Launch Checklist:

1. Get approval from event administration to set up pad, ELS, and rocket 2. Set up pad 3. Tip pad over and install rail 4. Check all tube interfaces 5. Slide rocket onto rail down to stop 6. Tip up launch pad 7. Stake pad to ground 8. Arm Electronics

a. Listen for proper beeps 9. Put igniter into motor and secure it 10. Connect launch clips 11. Connect ELS to battery 12. Clear launch area/back up appropriate distance 13. Make sure Ground Station and Pilots are ready 14. Get approval from event administration for launch

The following depend on procedures outlined by event administration:

15. Check to see if range and skies are clear 16. Insert key into ELS check continuity

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17. Countdown from 5 18. Launch 19. Remove key from ELS 20. Disconnect ELS from battery 21. Recover Rocket and UAV

3.6 SAFETY AND ENVIRONMENT

3.6.1 IDENTIFICATION OF SAFETY OFFICERS

Andrew Wimmer will be the primary rocket safety officer for the team. Ben Corbin is the team’s MIT EHS representative and is the assistant safety officer and is in charge of safety issues not directly related to the rocket. Both team members have considerable experience in their respective areas.

3.6.2 ANALYSIS OF FAILURE MODES AND MITIGATIONS

The following table provides a preliminary analysis of the failure modes of the proposed vehicle design, integration and launch operations.

TABLE 3-6: POTENTIAL FAILURE MODES

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3.6.3 PERSONNEL HAZARDS

A listing of personnel hazards and evidence of understanding of safety hazards is provided in the sections below.

Safety Checklist

In order to assure a safe and successful flight, a checklist must be followed during prep activities and launch. In order to reduce personnel hazards during the prep of the vehicle before taking it to the pad, the following precautions must be taken.

• Always wear safety glasses when dealing with rocket parts containing small hardware or pyrotechnic charges.

• Never look down a tube with live pyrotechnic charges in it. • Always point rocket and pyrotechnic charges away from body and other people • Avoid carrying devices that have live electrical contacts (radios, cell phones, etc.)

while prepping live pyrotechnic charges. • Never arm electronics when rocket isn’t on pad unless the area has been cleared

and everyone knows that pyrotechnic continuity checks are being done. • Always follow the NAR/TRA safety codes. • Always follow all applicable local, state and national laws and regulations • Do not allow smoking or open flames within 25 feet of the motor or pyrotechnics. • Make sure the checklist is followed and all steps are completed properly in a

thorough, workmanlike manner to assure mission success.

To further ensure mission success, considerations must be taken while at the launch prepping and flying the vehicle to keep all the people around and the vehicle itself safe. Important safety related considerations are found in the following list:

• Always follow the NAR/TRA safety code. • Adhere to local, state and federal regulations. • Never arm electronics unless rocket is vertical and the criterion for testing

continuity listed above is met. • Never proceed with launch if there are any outstanding technical issues that may

reduce the chances of a safe flight without first consulting both safety officers and NASA officials if needed.

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• No smoking or open flames within 25 feet of the vehicle. • Do not put self or others in path of body tube in case of early ejection on the

ground; always be aware of the possibility of ejection charges firing at any time. • Verify that ignition leads are not live before connecting igniter to ground control.

(A simple test is to touch the leads together in the shade and listen and watch for sparks, or place against tongue)

• Verify rocket will exit launching device vertically with almost no friction from the launch guides

• Verify that ground around launch pad is cleared of flammable materials.

Tool Use Injury Potentials and Mitigations

Tool: Injury Potential: Risk mitigation procedure:

Electric Handheld Sander Burns, cuts, skin abrasion Avoid loose clothing

Soldering Iron Burns Exhibit care not to come in contact with hot element

Table Saw Cuts, Limb/appendage

removal

Avoid loose clothing, follow safety procedures found in

instruction manual.

Wood Lathe Cuts, broken appendages Avoid loose clothing, use proper tools and safety

equipment

Table Router Cuts, Limb/appendage

removal Use proper protective gear.

Drill Press Cuts, abrasion, loss of

limbs/ appendages Use proper protective gear, hold down work with clamps

Miter Saw Cuts, Limb/appendage

removal

Avoid loose clothing, follow safety procedures found in

instruction manual.

Band Saw Cuts, loss of

limbs/appendages Use proper protective gear.

Belt Sander Burns, skin abrasion No loose clothes, wear proper

protective gear (gloves)

CNC Water cutter Cuts, loss of

limbs/appendages

Only trained personnel use this tool (machine shop

employees)

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Safety Codes

The Tripoli Rocketry Association and the National Association of Rocketry have adopted NFPA 1127 as their safety code for all rocket operations. A general knowledge of these codes is needed and will be required by all team members. These codes are found in Appendix 6.

Hazards Recognition

The Hazards Recognition Briefing PowerPoint Presentation will be given prior to commencing rocket construction. It will cover accident avoidance and hazard recognition techniques, as well as general safety.

1) General a) Always ask a knowledgeable member of the team if unsure about:

i) Equipment ii) Tools iii) Procedures iv) Materials Handling v) Other concerns

b) Be cognizant of your own actions and those of others i) Point out risks and mitigate them ii) Review procedures and relevant MSDS before commencing potentially

hazardous actions c) Safety Equipment

i) Only close-toed shoes may be worn in lab ii) Always wear goggles where applicable iii) Always use breathing equipment, i.e. face masks, respirators, etc, where

applicable iv) Always wear gloves where applicable, e.g. when handling epoxy and other

chemicals 2) Chemicals

a) The following are risks of chemical handling: i) Irritation of skin, eyes, and respiratory system from contact and/or inhalation

of hazardous fumes. ii) Secondary exposure from chemical spills iii) Destruction of lab space

b) Ways to mitigate these risks: i) Whenever using chemicals, refer to MSDS sheets for proper handling ii) Always wear appropriate safety gear iii) Keep work stations clean iv) Keep ventilation pathways clear v) Always wear appropriate clothing

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3) Equipment and Tools a) The following are risks of equipment and tool handling:

i) Cuts ii) Burning iii) General injury

b) Ways to mitigate these risks: i) Always wear appropriate clothing, e.g. closed-toed shoes. ii) Always wear appropriate safety equipment iii) Always ask if unsure iv) Err on the side of caution

4) Composites Safety a) Carbon fiber, fiberglass, epoxy, and other composite materials require special

care when handling. b) The following are risks composites handling:

i) Respiratory irritation ii) Skin irritation iii) Eye irritation iv) Splinters v) Secondary exposure

c) Ways to mitigate these risks: i) Always wear face masks/respirators when sanding, cutting, grinding, etc., lay-

ups. ii) Always wear gloves when handling pre-cured composites iii) Always wear puncture-resistant gloves when handling potentially sharp

composites iv) A dust-room has been constructed, as per MIT EHS guidelines, specifically

for the handling of composite materials. d) No team member will handle carbon fiber until properly trained

3.6.4 ENVIRONMENTAL CONCERNS

• All waste materials will be disposed of using proper trash receptacles • Biodegradable and flame resistant recovery wadding will be used • Solid rocket motor manufacturers’ instructions will be followed when disposing of

any rocket motor parts • Consideration of environmental ramifications will be made regarding applicable

activities • Proper blast shields on the launch pad will be used to prevent direct infringement

of rocket motor exhaust on the ground • Waste receptacles (trash bags) will be available for use around the prep area to

encourage proper disposal of waste from rocket prep activities • The following list of materials have been identified as potentially hazardous:

a. Aeropoxy 2032 Epoxy Resin b. Aeropoxy 3660 Hardener

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c. Ammonium Perchlorate Composite Propellant d. Black Powder

See Appendix 7 for complete MSDS specifications on these materials.

4 PAYLOAD CRITERIA

4.1 SELECTION, DESIGN, AND VERIFICATION OF PAYLOAD EXPERIMENT

4.1.1 MISSION STATEMENT AND SUCCESS CRITERIA

The payload will meet the following objectives:

1. Fly for 30 minutes by autopilot 2. Navigate to locations determined by a human operator 3. Gather atmospheric and video data 4. Fit inside the 6.5in rocket tube 5. Unfold and attain level flight after ejection from the rocket 6. Land without damaging the aircraft

4.1.2 UAV MILESTONE SCHEDULE

• 9/10: Project initiation • 11/19: PDR materials due • 12/1: Stability analysis completed • 12/5: Prototype without folding mechanisms completed • 12/10: Test launch with only vital electronics • 2/1: Prototype with folding mechanisms completed • 1/24: CDR materials due • 2/20: Full-scale Test from Balloon • 3/21: FRR materials due • 4/14: Competition launch

4.1.3 UAV DESIGN

Figure 4-1 below shows the completed UAV. A detailed description of its components follows.

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FIGURE 4-1: THE UAV

Fabrication Overview

The molds for the UAV wings will be made out of Foamular 250 which will be cut on a computerized foam cutter. Each foam wing mold will be made in 3 parts (Shown in Figure 4-2 and Figure 4-3). Part 1 will be connected to part 2 by a joint which allows the wing to fold up inside the rocket. The plastic hardware (tip protectors and rotator connections) will then be epoxied to the foam. Mold 1 will then be wrapped separately in fiberglass. Mold 2 and 3 will be wrapped, together, in fiberglass. The finished wing can be seen in Figure 4-1: The UAV.

FIGURE 4-2: LEFT WING

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FIGURE 4-3: RIGHT WING

The fuselage mold will be made of wood which will be cut on a CNC lathe. The mold will then be cut in half. Fiberglass will be laid-up in the mold halves. The mold will then be removed. The fuselage is made in two parts to allow easy placement and access for the avionics and flight mechanisms. Before flight, the two halves will be attached together with latches and the seam between them will be covered with tape. The nose will be made using polycarbonate. The nose is made of clear plastic to allow a wide field of view for the camera which will be placed in the nose.

FIGURE 4-4: BUILDING THE FUSELAGE

The vertical tail will be fabricated in 2 sections and the horizontal tail will be fabricated in 3 pieces. Pieces 1 and 2 (Figure 4-5: Tail Molds) will be epoxied together. The parts will then be wrapped in fiberglass. Hinges will connect all the pieces together which is discussed in more detail in the Folding Mechanisms section.

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FIGURE 4-5: TAIL MOLDS

Fuselage

Summary of Fuselage Attributes:

• Fuselage Length (Lf) = 45 in • Largest Fuselage Diameter = 3 in • Center of Gravity (Measured from Nose) (xcg) = 0.25Lf = 11.3 in • Distance from Wing Leading Edge to Nose = 9.1 in • Total Weight (W) = 7 lbs

The fuselage will be 3 in at its largest section, which will be roughly underneath where the wings are mounted. This diameter was chosen in order to accommodate the largest avionics equipment. Aft of the wings, the body will taper down to a diameter of roughly 2 in.

The motor and a folding propeller will be located at the rear of the aircraft which will allow an unobstructed view for the camera at the front of the aircraft and it will allow the propeller to automatically fold back when it stops spinning. A folding propeller is used to ensure that the UAV fits inside the rocket. The propeller will also fold up while gliding to reduce drag and upon landing to avoid incurring damage. The bottom of the UAV will be flattened slightly in order to accommodate two skid plates, made of Kevlar-epoxy, which will protect the UAV body when it lands.

The center of gravity will be located 25% of the fuselage length from the nose (9.1 in), which will be accomplished by putting the heavy avionics equipment in front of the wings. The center of gravity was chosen to be so far forward to allow the wings to fold

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up without hitting the vertical stabilizer. A stability margin (S.M.) of 0.1, a horizontal tail volume coefficient (Vh) of 0.5, and a horizontal stabilizer aspect ratio (ARh) of 4.5 were used to estimate the location of the neutral point and the aircraft wing. These values were chosen to increase the stability of the airplane.

[Wing Aspect Ratio (AR) = 10.8]

�.�. = ��� − ����

The estimate of the neutral point of the aircraft is 2.6 in from the wing leading edge. This estimate puts the center of gravity of the UAV 2.2 in from the wing leading edge. With this information, we then calculated the distance from the nose to the wing leading edge to be 9.1 in (wing chord is 5 in).

Wings

Summary of Wing Attributes:

• Wing Span (S) = 54 in • Wing Chord (c) = 5 in • Angle of Attack while Cruising (α) = 3° • Airfoil: NACA 4412 • Dihedral (Υ) = 5.8° • Coefficient of Lift (CL) = 0.778 • Wing Coefficient of Drag = 8.51E-3 • Total Lift = 7.00lbs • Cruising Altitude (h) = 2500ft • Cruising Air Speed (V) = 66.0 ft/sec • Glide Ratio = 0.08 • Stall Angle of Attack = 14°

The wings will have a chord of 5 in which was chosen because it is the largest chord that will still allow the UAV to fit inside the rocket. Using this chord we then plotted coefficients of lift and drag for various angles of attack using Xfoil (Xfoil is a popular developed at MIT command line program which analyzes airfoils). A Reyonlds number for the analysis was calculated using

� = ��

[ν = kinematic velocity of air]

xnp

c≅ 1

4+

1+ 2AR

1+ 2ARh

1 − 4

AR + 2

Vh

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(Xfoil uses Reynolds numbers without chord). A cruising flight speed (V) of 66.0 ft/sec (45 MPH) was used. At an expected cruising altitude of 2500 ft, the kinematic velocity of air (ν) is nearly 1.52E-4 ft^2/sec, which results in a Reynolds number of roughly 180,000.5 As an aside, the kinematic velocity of air was found using a temperature of 50.1°F which was estimated with the following equat ion:

� ≅ 59 − 0.00356 ∙ ℎ

Using this Reynolds number, nine airfoils were analyzed. The 6 airfoils with the highest CL are shown in Figure 4-5.

5http://www.engineeringtoolbox.com/air-absolute-kinematic-viscosity-d_601.html

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FIGURE 4-6: AIRFOIL COMPARISON

The leftmost graph shows the coefficient of lift plotted against the coefficient of drag. The center graph shows CL vs. α (the steeper graph) as well as the pitching moment (Cm) vs. α (the flatter graph). After some consideration, the NACA 4412 was chosen because it has a very high ratio of CL/cd and it has one of the highest CL around an angle of attack of 3°, which will be the UAV’s angl e of attack while cruising. The 3° angle of attack was chosen because it provides significantly more lift but doesn’t produce too much drag.

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At a 3° angle of attack, the NACA 4412 airfoil has a coefficient of lift of 0.778. The stall angle of attack at 66.0 ft/sec was determined to be roughly 14° (shown in Figure 4-7: NACA 4412 Polar). The glide ratio and glide angle at 3° are 0.08 and 4.6° respectively.

FIGURE 4-7: NACA 4412 POLAR

After having chosen an airfoil, calculations for total weight were made with the equation:

� �������

2

[Density (ρ) = 2.21E-3 slugs/ft3]

A wingspan of 54 in was then chosen because it allows the aircraft to lift 7 lbs, roughly the estimated weight of the airplane, while flying at its cruising speed.

Each wing will be horizontal for 3.5 in on either side of the aircraft and will then have a 5.8° dihedral ( Υ) for the rest of the wing in order to increase spiral stability. A dihedral of 5.8° was chosen using:

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= ������

[B = 4; lv= 29.3 in]

In this equation, Υ actually refers to the equivalent dihedral angle but in our approximations we ignored the contributions of the flat center section of the wing to the dihedral. The equivalent dihedral will be calculated more accurately in the future when a more thorough stability analysis is performed.

Tail

Summary of Tail Attributes:

Horizontal Tail:

• Taper Ratio = .4 • Aspect Ratio (ARh) = 4.5 • Volume Coefficient (Vh) = 0.5 • Moment Arm (lh) = 29.3 in • Span = 10.7 in • Average Chord = 2.3 in • Root Chord = 3.2 in • Tip Chord = 1.3 in • Airfoil = NACA 0008

Vertical Tail:

• Taper Ratio = .4 • Aspect Ratio (ARv) = 1.4 • Volume Coefficient (Vv) = 0.05 • Moment Arm (lh) = 29.3 in • Span = 6.2 in • Average Chord = 4.2 in • Root Chord = 6.0 in • Tip Chord = 2.4 in • Airfoil = NACA 0008

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FIGURE 4-8: VERTICAL TAIL

FIGURE 4-9: HORIZONTAL TAIL

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The UAV tail will consist of a vertical stabilizer and a horizontal stabilizer mounted part way up the vertical stabilizer. The horizontal stabilizer is mounted away from the fuselage in order to maximize its area while minimizing the total width of the airplane. Both the horizontal and vertical tails will be made using the NACA 0008 airfoil. This airfoil was chosen because it is symmetric and has a slightly smaller thickness/chord ratio than the wing.

Control surfaces for the aircraft will consist of elevators and a rudder located on the tail. They will be controlled with pushrods originating from servos located in the fuselage.

For size estimates, a horizontal tail volume coefficient of .5 and a vertical tail volume coefficient of .05 were chosen in order to increase stability which is important for the autopilot to function. These values may be altered experimentally after a prototype airplane has been tested depending on whether stability needs to be increased or decreased. The following equations were used for estimates of tail sizes.

� = ������

� = ������

Typical aspect ratios of 4.5 and 1.4 were chosen for the horizontal and vertical tails respectively. Furthermore, taper ratios of .4 were used on both the horizontal and vertical tail. This resulted in the following tail dimensions:

Horizontal Tail

• Root Chord: 3.2 in • Tip Chord: 1.3 in • Span: 10.7 in

Vertical Tail

• Root Chord: 6.0 in • Tip Chord: 2.4 in • Span: 6.2 in

Motor

The UAV will be powered by a brushless motor and a Graupner folding propeller. The motor will be powered by a brushless motor controller and a lithium polymer battery.

Folding Mechanisms

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FIGURE 4-10: FOLDED UAV

Wing Rotating Mechanism

In order to fit inside the rocket, the wings, horizontal stabilizer, and horizontal stabilizer will all have to fold which will be achieved by way of the following mechanisms:

The wings will be attached to the spring loaded rotating mechanism shown in Figure 4-11: Wing Rotating Mechanism. The mechanism allows one wing to lift above the other. Both wings will then fold backwards which is shown in Figure 4-10.When unfolding, a torsion spring will swing both wings out until they achieve a 180° angle with each other. Wires running from the wings to the fuselage will prevent the wings from rotating past 180°. A compression spring will then pull the elevated wing down into position. Latches will be placed on both wings which will connect to protrusions from the fuselage to keep the wings from moving after being deployed.

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FIGURE 4-11: WING ROTATING MECHANISM

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FIGURE 4-12: WING ROTATING MECHANISM

A few inches away from the fuselage, the wings will contain two additional hinges which will allow part of the wings to rotate upwards to create the 5.8° dihedral.

The vertical tail will separate into two halves with the top half folding down. The horizontal tail will separate into 3 parts and fold down below the aircraft. The folded tail is shown in Figure 4-13. Both surfaces will fold back in place during flight with the assistance of torsion springs or flexible strips of material and will then be held in place by magnets embedded in each piece. Hinges for the tail folding will be made from either polycarbonate or Kevlar that is coated in epoxy and fractured at the hinge joint.

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FIGURE 4-13: TAIL SURFACE

4.1.4 AVIONICS DESIGN AND SUBSYSTEMS

Sensors

There shall be two sets of atmospheric sensors; one set connected to the flight computer for transmission to the ground station and for logging to onboard volatile memory, the other set connected to an independent board which logs the atmospheric data to an SD card. There shall also be two means of collecting visual data; a modified digital camera which can be commanded to take a photograph via the flight computer and a separate board to transmit real-time video data to the ground-station. These systems combined will be used to fulfill the SMD payload requirements to log atmospheric data (temperature, pressure, UVI, solar radiation and humidity) at a rate of at least once every 5 seconds and take more than two still during flight and three after landing.

TABLE 4-1: SENSOR SPECIFICATIONS

Data Board Sensor Lower Limit Upper Limit Resolution

Temperature HTS3-R1-A Dallas

Semiconductor DS18S20

-55oC (-67°F)

125oC (257°F) 0.5 oC (0.9°F) UVI2-R1-A

Ultraviolet UVI2-R1-A 0 16 0.1

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Solar HTS3-R1-A Clairex CLD140

Humidity HTS3-R1-A Honeywell HIH-4000-001

0% 100% 3.5%

Pressure SCP1000 Breakout

SCP1000-D01 30,000Pa (4.35psi)

120,000 Pa (17.40psi)

6Pa (8.7E-3 psi)

Sensor Hardware

Hobby Boards HTS3-R1-A

This sensor measures temperature, humidity, and solar radiation. The range for the humidity sensor is 0-100% relative humidity. The range for the temperature sensor is -55 - +125 degrees Celsius. Finally, the response for the solar sensor ranges from visible light to infrared (850nm peak response). This device is intended to meet the SMD requirement of collecting the atmospheric measurements of temperature, relative humidity, and solar irradiance. This real time sensor meets the minimum data collection rate requirement of one measurement per 5 seconds during flight.

Hobby Boards UVI2-R1-A

This sensor measures UV radiation in both the UVA and UVB spectrum (280nm to 400nm), with a 365nm wavelength peak response. The device will register data by reporting a UV Index from a standard scale of 0-16. This device is intended to meet the SMD requirement of collecting the atmospheric measurement of ultraviolet radiation. This real time sensor meets the minimum data collection rate requirement of one measurement per 5 seconds during flight.

SCP1000 Breakout

This barometer measures atmospheric pressure from 30 to 120kPa. This device is intended to meet the SMD requirement of collecting the atmospheric measurement of pressure. This real time sensor meets the minimum data collection rate requirement of one measurement per 5 seconds during flight.

Canon PowerShot A470 7.1 MP Digital Camera

This provides the ability to take still images independently of the real-time video stream. The camera can be commanded to capture and image from the ground station and the resulting images are stored on an SD card external to both sensor data logs, so they can be retrieved post-flight.

CMOS Camera - 640x480

This provides the video data to the AVS-2400 board, which is then transmitted in real-time back to the ground station.

Data Logging

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Arduino Uno

Acts to interface between the back-up sensor boards and the SD card hardware. As a back-up system, this is entirely separate from the flight computer. This also processes the data so it is in a usable format when saved and controls the rate at which the sensor data is logged. As part of the back-up system, this helps fulfill the SMD requirements for redundancy.

DOSonCHIP FAT16 FAT32 uSD Module

This provides the hardware requirements for logging sensor data to an SD card. As a part of the back-up system this helps fulfill the SMD redundancy requirements.

Software

The backup data-logging board must be programmed. This piece of code must poll the sensors for readings at regular intervals, process the resulting data so it is in a usable format, and then save this data into a file on a micro-SD card.

Placement

The UV Sensor (UVI2-R1-A) will be located either directly behind or in front of the wings. A ‘window’ will be made in the top of the fuselage of the UAV using a UV transparent material, which will allow the penetration of UV rays to be detected by the sensor. A Temperature/Humidity/Solar sensor (HTS3-R1-A), flush with the surface to reduce impact on aerodynamics, and a pressure sensor (B1-R1-A) will also be installed in the fuselage of the UAV. A pressure sensor shall also be mounted on the flight computer board to gain supplementary pressure data. Additionally, a video sensor will be installed (AVS-2400-1000-KX171-G2) in the nose of the plane with at a 30° slant from the horizontal via flush mounting. With its high field of view, it will assist in reconnaissance and location of mission targets.

Transmission

The manual flight control is the standard handset used for RC aircraft, whose antenna will be modified to increase its gain. Its use should not be necessary as the onboard flight computer is able to control the UAV.

The telemetry and command uplink system interfaces directly with the flight computer. The command uplink enables the user at the ground station to upload waypoints for the UAV to fly to in real time. The telemetry downlink provides real time transmission of the atmospheric data required for the SMD payload, which will be logged by the ground station computer. Since this data is also being logged by the flight computer, this provides an extra level of redundancy.

The video link is a separate piece of hardware which provides real-time video transmission from the UAV’s onboard camera directly to the user at the ground station,

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aiding in flying and providing a bird’s-eye-view deemed essential for the concept outlined in the initial proposal. This also adds an extra level of redundancy as still-images can be taken directly from the video stream at the ground station.

Hardware

AVS-2400-1000-KX171-G2

This provides the video transmission handling for the CMOS camera on the UAV, transmitting the visual data in real time to the ground station, which gives the user a first person view at the ground station. This also acts to fulfill the redundancy requirements for the SMD, as still images may be taken from the video feed at the ground station, providing a backup for the Canon A470 still image capturing.

Redundancy

Sensor redundancy is provided in several ways. The atmospheric sensor portion of the payload will achieve redundancy by having a second set of sensors external to the flight computer, which also logs data to non-volatile memory (for collection later), thus if the flight computer fails to log sensor data, the payload is still able to log data while the UAV is flown using standard RC equipment. It is also worth noting that both the UV sensor board and the humidity, solar and temperature boards monitor temperature, so there is innate redundancy in the temperature measurements. There is also redundancy for the image capturing; in addition to carrying a modified digital camera that can be commanded from the ground station to take photographs, still-images can be captured from the real-time video stream, which is entirely separate from the flight computer.

Avionics

Avionics Hardware

ArduPilot Mega

Provides GPS and transmits data via a 900MHz data-link to the ground station. This device is intended to meet the SMD requirement of having the payload carry a GPS tracker as well as the SMD requirement of transmitting data from the payload to the ground station. This also acts as the flight computer, flying the UAV and maintaining stability based on the user’s inputs at the ground station.

Software

Since we will be using the ArduPilot Mega hardware, we will also be customizing the ArduPilot Mega software, which requires minimal modification to adhere to the SMD requirements. There are two main modifications required for SMD: the first is to modify the data-logging sub-routines to include the atmospheric data from the respective sensors. Additional modification is required so that post-landing; the data is transmitted through the telemetry down link, on top of the real-time transmission that will occur.

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The ground station will provide the primary interface for controlling the UAV. The ground station software will run on a computer with means of displaying the video data streamed directly from the UAV. This will be combined with a method of commanding the UAV’s target location, choice of landing location, and still capturing on a secondary digital camera. Furthermore the atmospheric data from the UAV downlink will be displayed to the user and stored in a file, and there will be an option to save stills from the real-time video feed.

Redundancy

Redundancy is provided in several ways. First, the flight computer contains both a GPS receiver and an inertial measuring unit. In the event that the GPS sensor loses communication with the satellite, position data can still be obtained (albeit with an error that increases over time) from the inertial measuring unit. The three main systems will use different transmission frequencies: the manual flight control system will use a 72MHz frequency band, as is standard for model aircraft; the telemetry and command uplink will use 900MHz; and the video link will use 2.4GHz. These frequencies have been chosen as they are commonly used and do not interfere with each other. The utility of placing these three systems on three different frequencies is increased redundancy; a failure in any one of these systems will not result in a loss of mission.

4.1.5 ELECTRONICS DESIGN AND SUBSYSTEMS

Power Supply

Two lithium polymer batteries will provide power for the motor, sensors and avionics. One of the batteries will be dedicated towards powering the motor, while the other will power avionics and sensors to create a power source redundancy in case one was to fail. They will be located inside the fuselage in a position to provide ballast in order to adjust the center of gravity to a position ideal for UAV control and stability.

Motor

The UAV will be powered by a brushless motor and a Graupner folding propeller. The motor will be powered by a brushless motor controller and a lithium polymer battery. A separate lithium polymer battery will be used to power the UAV electronics and control surfaces so that, in case the motor battery fails, the airplane can still glide and land safely.

4.2 PAYLOAD CREATIVITY AND ORIGINALITY

The idea of a deploying an Unmanned Aerial Vehicle (UAV) with a rocket is not an entirely original idea; however, the end goal of producing a simplified flight control

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interface is a new idea. Current UAV technology requires a classically trained pilot to remotely fly the craft, or at the very least requires operators to undergo a large amount of training in the operation of remote controlled equipment. The control interface that the MIT Rocket Team is developing aims to reduce the amount of training required to successfully complete a UAV mission, opening this class of technology to a greater range of potential users. As such a simple “point-and-click” flight system is being developed to easily translate user operations into functional flight controls, allowing for successful operation with little or no operator training. Furthermore, by choosing a rocket deployment, and keeping to a $5000 budget, it further allows for this technology to be applied to situations where time and budget are controlling factors. This quick deployment and relative low cost of operation would ideally suit the needs of search and rescue operations, reconnaissance missions, and even rapid scientific data gathering missions.

By completing NASA’s Science Mission Directorate, the MIT Rocket Team is further proving the range of applications the UAV is capable of completing. The requirements of the SMD do not explicitly require the complexities a UAV. However, by using the UAV form factor, the MIT Rocket Team is able to complete all required tasks of the SMD mission to accuracy unattainable with other forms of payload. For example, during flight, a UAV will generally maintain the same orientation with respect to the horizon, allowing for all images taken during and after the flight to keep the sky and ground in the same location with a very low chance of error. Furthermore, the use of a controllable payload allows for the investigation of specific areas, allowing for the gathering of data of greater importance while limiting the need for secondary missions. Finally, the use of a UAV allows for a greater amount of data to be collected due to the extended flight time of a UAV platform compared to other payload options.

4.3 SCIENCE VALUE

4.3.1 SCIENCE PAYLOAD OBJECTIVES

There are two different aspects to the payload, each with their own objectives; the SMD payload requirement and decreased complexity in UAV flight.

The payload objectives relating to the SMD payload are to log atmospheric pressure, temperature and humidity along with solar intensity and UVI data at 5second intervals as well as taking at least 2 still during flight and 3 after landing.

The payload objectives relating to decreasing the complexity in flying a UAV is to complete the flight (visually locating the rocket and landing) solely using the software provided at the ground station without reverting to back up manual control.

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4.3.2 PAYLOAD SUCCESS CRITERIA

The data logging and sensors shall be deemed successful if the payload obtains and logs atmospheric pressure, temperature and humidity along with solar intensity and UVI data at 5second intervals as well as taking at least 2 still during flight and 3 after landing. It shall be deemed a success regardless if the data is collected by the main or the back-up sensor package.

Fulfilling the SMD payload requirement successfully shall also demonstrate the flexibility in the UAV design.

If the UAV operator successfully visually locates the rocket and lands in a state fit for reusability, without resorting to use of the back-up manual flight control then this will demonstrate successful reduction in complexity of UAV control.

4.3.3 EXPERIMENTAL LOGIC, APPROACH, AND METHOD OF INVESTIGATION

By using a science payload in a descending UAV, atmospheric measurements presented in section 4.2 will be collected. The science payload will be contained inside built-in compartments in the fuselage, preventing thrashing of instruments from launch initiation to landing of UAV.

To obtain such data, all the sensors will be turned on just prior to launch and measurements will be recorded at 5-second intervals during launch and decent within target area. Using a UAV to carry a science payload of multiple sensors and accurately obtain such data will provide a more efficient means for obtaining such data. Additionally, the telemetry devices inside the UAV will allow for safe operation of the vehicle via a pilot at the ground station. A single mission by a UAV with such science payload gathers data at varying altitudes effectively and efficiently, relative to other means of acquiring such data.

The goal of the UAV is also to have a simplified flight control interface. This will be achieved by having stability control on the UAV such that it is able to maintain straight and level flight, perform controlled turn and land safely with no user input. Combining this with an appropriately designed user interface, this should be sufficiently automated that it can be controlled by a person with absolutely no flying experience.

4.3.4 TEST MEASUREMENTS, VARIABLES, AND CONTROLS

Testing and verification of the avionics occurs in three distinct phases: ground testing, on a test aircraft and lastly on the final UAV, thus enabling ground testing shall consist of validating the correct operation of all hardware and sensors in a non-critical environment. The testing on the test aircraft serves to verify that the subsystems within the avionics system work as expected in flight case and to validate changes made to the flight computer hardware and software for the purposes of the competition. The

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flight testing on the UAV is to demonstrate the avionics system is able to function correctly in its intended flight configuration and importantly, that is it capable of recovery after deployment from the rocket.

Phase One – Ground Testing

First the flight computer, GPS/IMU, and telemetry boards shall be connected to ensure these systems are functioning. Next this system shall be connected to servos and a program will be used to actuate the servos in a known fashion to confirm that the servos can be controlled. Furthermore, an R/C receiver will be attached to the avionics system to ensure that the equipment accepts commands from an R/C handset. The telemetry system shall also be tested by communicating the position the GPS reports to a mock-up ground station. That position will be checked for accuracy, the time taken for the GPS to get position lock at start up will be noted, and whether or not the GPS is able to maintain lock when moved at a reasonable speed will be checked.

The back-up board will also be constructed and be tested by exposing it to a variety of conditions such as varying the altitude under different weather conditions and comparing to the expected values. This acts to validate that both the sensors and the data recording systems within the back-up board are working correctly.

The real-time video system will also be tested by varying the distance between the transmitter and receiver to find the limit of the range the system is able to adequately transmit the video data.

Phase Two – Test Aircraft

The initial flight testing will occur on a commercially available R/C aircraft. This acts to limit the dependency of avionics testing and refining on the construction of the UAV, thus expediting the development of the avionics. This also minimizes the risk to the final UAVs; there will be at least one back up UAV in the event that the primary UAV fails or breaks.

The initial flights will be manual, i.e. the R/C aircraft shall be controlled solely by an operator using a standard R/C controller. These initial flights will be to verify the correct setup of the flight computer and servos. After that, flight testing shall be undertaken to tune the control gains of the flight computer for stable flight. It is worth noting that these gains will not necessarily be those required for the final UAV, but the autonomous flying ability gained from this is essential for further flight testing. Next flight tests shall be performed where coordinates of waypoints to be flown to will be uploaded to the avionics system in-flight to ensure that this functionality works as expected. At this point, the flight computer hardware will be wired to the primary sensors. Also, the flight software shall be modified to log the sensor data on the internal volatile memory and transmit the logged data post landing. This additional functionality shall then be tested in multiple flights to ensure correct operation. Over the course of the latter flight testing,

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the back-up sensor board, real-time video transmission and still capturing systems shall be integrated into the R/C aircraft, tested and refined as necessary.

Phase Three –UAV Testing

After the avionics performance has demonstrated adequate performance on the ‘Test Aircraft’, the avionics system shall then be integrated with the UAV. The first flight testing shall be to determine the control gains required for stable flight of the UAV. For the purposes of these tests, the equipment not essential for flying (i.e. everything but flight computer, telemetry link and GPS/IMU) shall be replaced by appropriate ballasting to minimize the risk of damage to components.

Once adequate control gains have been determined, a series of flight tests stall be undertaken to ensure that the sensor systems and data logging systems, as well as the imaging systems, still function as desired. These flights will also determine if the propulsion system’s duration and thrust are sufficient to maintain steady-level flight for at least 30 minutes. Further testing representative of flight scenarios shall also be undertaken, including point-to-point flying based on user inputs at a ground station.

Drop tests from a tethered weather balloon shall also be used to simulate UAV deployment to ensure the UAV/Avionics is capable of recovering from the post-deployment dive. The UAV will be unpowered (propulsion system off) due to safety reasons for these tests; the lithium polymer propulsion battery will be replaced by ballast to mitigate the risk of the lithium polymer battery exploding due to damage if the UAV were to crash. Gliding should be sufficient to test all avionics. A test section of the rocket body tube will be hung from a balloon platform attached to the weather balloon. The UAV will be packed into the sabot, and the sabot will be placed in the body tube and connected to a radio controlled remote triggering/dropping device. The balloon will be raised and tethered at an altitude of approximately 200 ft; this altitude should be sufficient for full UAV deployment, while restricting the safety radius needed to be cleared of personnel on the ground to a reasonable value. Then the sabot will be dropped under drogue parachute, and the UAV will deploy. These tests shall be performed with ballast instead of non-essential electronic components. This ballast will be placed in such proportions and arrangements to maintain the center of mass of the UAV, providing sufficiently accurate mission conditions for the UAV.

4.3.5 RELEVANCE OF EXPECTED DATA

The data collected is vital for the analysis of the systems and subsystems in determining any necessary changes to the design of the UAV, or to any instruments and power devices. Accuracy of the data is also significant in that, if the lift produced or propeller propulsion is not enough, the UAV will need to adjust its attitude, which can potentially lead to unbalanced forces, instability of the vehicle, or even stalling of wings or horizontal stabilizer.

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Effectively, all data on the stability lift and drag forces for the wings, horizontal stabilizers, and the assembled body must be accurate to determine the necessary attitude of the vehicle to achieve specific tasks, such as steady-level flight, landing, and elevating altitude.

The various measurements of the atmosphere will be gathered, organized and analyzed to study changes in the atmosphere with changes in altitude, changes in amount of atmosphere between the payload and ground, and changes in level of atmosphere between the payload and space. This will provide real data, to contrast to theoretical data predicting such qualities of the atmosphere based on location, altitude, and density of the air.

4.3.6 ACCURACY AND ERROR ANALYSIS

Accurate data provides information about atmospheric conditions to people, giving realistic data for the analysis and design of different potential aerial mechanisms. Such data will also allow for scientific groups to consider the protection necessary for instruments of varying sensitivity to cosmic electromagnetic radiation, that are planned on being deployed at varying altitudes. Devices and forces can be greatly affected by variables such as pressure, temperature, relative humidity, solar irradiance, and UV radiation; appropriate knowledge of such variables can allow for proper preparation for objects entering such conditions.

4.3.7 PRELIMINARY EXPERIMENT PROCESS PROCEDURES

• Individually test all sensors for temperature, pressure, relative humidity, solar irradiance, and UV radiation (primary and back-up sensors).

o Pressure can be tested in a wind tunnel with a known dynamic pressure o Temperature probes can be tested at room temperature, and outside ambient

temperature, which will range from 30 °F to 60 °F, at time of anticipated testing

o Relative humidity can be tested in dry rooms and in ambient air, with known humidity levels known from known weather conditions.

• Determine mass of all instruments, avionics, and power devices • Estimate mass of UAV body materials • Identify a suitable propulsion system and battery for device powering • Using computational software, Excel and MATLAB, verify calculations for expected

parameters and requirements of the UAV. • Using CAD software, model UAV with appropriate dimensions and parts. • Use flight simulation software to determine flight patterns of UAV • Develop mission success criteria

o All data accurately acquired and stored properly o Still photographs acquired at SMD prescribed intervals o Communication between payload and ground station seamless

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o Semi-autonomous navigation capable of navigating to command coordinates o Safe landing of rocket and tethered pieces with use of parachutes o Safe landing of UAV, employing protective underside coat

• Ensure rocket, UAV and other equipment are reusable after each mission

4.4 SAFETY AND ENVIRONMENT (PAYLOAD)

4.4.1 PERSONNEL HAZARDS

A listing of personnel hazards and evidence of understanding of safety hazards of the payload is provided in the sections below.

Safety Precautions

In order to assure safe and successful operations concerning the payload, a checklist must be followed. In order to reduce personnel hazards the following precautions must be taken:

• Avoid standing in the plane of the propeller when UAV propulsion system is on. • Do not try to catch the UAV during landing. • Make sure all relevant testing (reference checklist) has been completed prior to

attempting a flight test. • Make sure the checklist is followed and all steps are completed properly in a

thorough, workmanlike manner to assure mission success.

Lithium Polymer Battery Hazards and Procedures:

• Always charge lithium polymer batteries with a balancer. Out of balance packs can explode.

• Never over-discharge a lithium polymer battery (below 2.7V per series cell). • Never attempt to charge a lithium polymer battery if it looks bloated, damaged,

over discharged (below 2.7V per series cell). Damaged packs can explode. • Never leave a lithium polymer battery unattended while charging. • Always charge lithium polymer batteries on a non-flammable surface and away

from flammables. • Take extreme caution around the UAV in the case of a crash. The pack may

explode if damaged. • Never discharge a lithium polymer battery at more than the published discharge

rate. The pack may explode if discharged too quickly.

4.4.2 ENVIRONMENTAL CONCERNS

• All waste materials will be disposed of using proper trash receptacles • Consideration of environmental ramifications will be made regarding applicable

activities

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• The following list of materials have been identified as potentially hazardous: o Aeropoxy 2032 Epoxy Resin o Aeropoxy 3660 Hardener o Lithium Polymer Batteries

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5 ACTIVITY PLAN

5.1 BUDGET PLAN

To meet the budget needs set forth in the initial proposal, the MIT Rocket Team has reached out to three main sponsors. The largest percentage of funding will be provided by the Massachusetts Institute of Technology department of Aeronautics and Astronautics, in their support of undergraduate projects. The Massachusetts Institute of Technology Edgerton Center, and NASA’s Science Mission Directorate Grant will provide further funding to the MIT Rocket Team. A breakdown of financial contribution can be seen in Table 5-1, and a budget summary is shown in Table 5-2.

TABLE 5-1: FUNDING SOURCES

Funding Sources

Source Contribution MIT Aero-Astro $7,000 MIT Edgerton Center $5,000 NASA SMD Grant $5,000 MIT RT Savings $5,000

Total $22,000

TABLE 5-2: SYSTEM COST SUMMARY

System Cost Summary

System Sub-System Cost Quantity Total Cost

Rocket

Propulsion 562.99 1 562.99 Airframe-Body 429.00 1 429

Airframe-Fairing 70.00 1 70 Avionics 765.00 1 765

Payload Support Equipment

141.00 1 141

Recovery 444.29 1 444.288

UAV

Propulsion 369.94 1 369.94 Airframe 370.00 1 370

ACS 70.00 1 70 Avionics 378.80 1 378.8 Payload 700.00 1 700

Recovery 100.00 1 100

Support Ground Station 5,689.80 1 5689.8

Testing 2,000.00 1 2000

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Spares 4,000.00 1 4000 Team Support 4,260.00 1 4260

Totals 20,350.82 20,350.82

5.2 TIMELINE

As laid out in the MIT Rocket Team’s original USLI Proposal, a Gantt chart is being used to organize and track the team’s process. Since the submission of the proposal minor changes have been made due to changes in the team’s organizational structure. Furthermore a number of tasks have been pushed back due to design changes that became relevant in the process of completing initial development.

Important changes to note are the movement of the initial structural testing, search pattern development and testing, and the development of the ground station systems. These events were pushed back to a later date due to setbacks associated with the final design of the payload. With this revised schedule there is a greater need to work over the winter break, but many members of the team have already chosen to be on campus during this period. As such the team is still on track for completion on time.

A full scale version of the Gantt Chart can be found in Appendix 2.

5.3 OUTREACH PLAN

The team plans to hold four community outreach events over the next few months to inspire and educate the general public about space and space-related technologies in a hands-on fashion. The plan is to reach audiences ranging from classrooms of high school students, to auditoriums of both children and adults. Through a combination of presentations, demonstrations, and hands-on activities, our goal is to share our enthusiasm for science and engineering: in particular, rocketry.

The following table lays out these activities:

TABLE 5-3: OUTREACH EVENTS

Event Date Rocket Day at the Boston Museum of Science

Mid-January (tentative)

Rocket Day at the MIT Museum Mid-January (tentative)

MIT Splash Weekend 21 November MIT Spark Weekend March (tentative)

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Rocket Day at the Boston Museum of Science

The MIT Rocket Team has close ties with the MIT chapter of a national organization called the Students for the Exploration and Development of Space (SEDS), which aims to get undergraduates involved in space-related projects. These projects often have a community service dimension, and in the past the group has organized highly successful workshops and presentations at the Boston Museum of Science, where undergraduate and graduate students conduct hands-on activities for the purpose of increasing public interest in math, science and higher education. We plan to run a “Rocket Day” at the museum in mid-January, which will consist of a combination of presentations and hands-on activities and demonstrations.

We will be able to promote this event through various student websites and public radio, as well as the museum’s public relations personnel. We also plan to distribute posters and flyers around the museum.

We have gotten in touch with a member of museum staff who has hosted SEDS members in the past, and are currently working on securing a date and duration for the event. Tentatively, we plan on holding the event in mid-January, and running both a morning and an afternoon session, to accommodate two waves of visitors. The museum will most likely host us on their Science and Technology stage, which would give us the opportunity to address a large audience of all ages and backgrounds; we will try and maximize the amount of time spent engaging with them, and minimize the amount of time standing and lecturing.

The details on each of the activities are contingent on review by museum staff but our proposed list includes:

• Film canister rockets • Parachute construction • Shortwave radio communications (emulate mission control with delay) • Bottle rocket demonstration • Full-scale hobby rockets and scaled down models of famous rockets • Demonstrations to demonstrate the scales of larger rockets

The learning objectives for this activity will be the following:

Arrive at a basic understanding of the history of rocketry. We believe that understanding rocketry requires first learning about its development, which includes the figures and organizations that have been key to the field. Topics will include Wernher von Braun, NASA, the Space Race, and current commercial organizations such as SpaceX.

How does a rocket work? The main premise for this activity is to explain how rockets work and prime our target audience with an interest in math and science through the amazing technology that are rockets. This portion of the presentation

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will introduce the importance of math and science in developing rockets by explaining the basics principles that allow us to send rockets into space. Hands-on activities will be used to ensure a rich understanding of the basics of projectile motion.

The social impact that low-Earth orbit rocketry has brought to our everyday lives. This portion of our presentation will explore the invaluable contributions that rockets have brought to our society from advancing our telecommunication capability to allowing accurate weather forecasts to creating a paradigm shift into our technology embedded world.

To evaluate the success of our engagement, we plan to include a question session with the audience, and examine the accuracy of their responses based on our presentations and activities. Ideally, we would use entrance and exit surveys to quantitatively measure the success of our public outreach in meeting our educational goals. However due to the large range of ages expected, an interactive conversation is more practical.

Planned presentations and lesson plans are located in the appendix.

Rocket Day at the MIT Museum

We plan to run a nearly identical event at the MIT Museum, which is an administrative department of the Institute. The nature of the audience will allow us to be slightly more technical in our presentation, and will expand the range of people we reach through our efforts.

As with the Museum of Science, SEDS members have had successful experiences with presenting at the MIT Museum in the past. We have gotten in touch with a member of museum staff who has hosted us previously, and are currently working on securing a date and duration for the event.

MIT Splash and Spark Weekends

MIT’s Educational Studies Program is a student group that offers services to student and community members alike. It offers weekend-long, student-taught classes during November (called Splash) and March (called Spark) to a target group of 7th-12th graders. Classes are taught on campus, and we intend to offer several of these during each period. Splitting up the curriculum into each of the three learning objectives and the activities related to each would be ideal. Since these classes would be smaller and engaging, we plan to use entrance and exit surveys to quantitatively gauge the learning that occurred. This will be useful to know if we need any changes to the curriculum before presenting at the museum (which will occur after Splash).

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6 CONCLUSION

For its entry into NASA’s University Student Launch Initiative, the MIT Rocket Team has chosen to develop a simplified flight control interface to use in conjunction with a Unmanned Aerial Vehicle to be deployed at 2500 ft by a custom designed and fabricated carbon fiber rocket. The team’s main goal in completing this challenge is to develop a method that will allow for a significant reduction in the skill and training needed for the successful operation of a UAV. With this in mind the MIT Rocket Team anticipates that in the near future UAV flight systems similar to the one being developed will be used on a greater scale than before for a wide variety of missions ranging from search and rescue, to reconnaissance and even rapid scientific data acquisition.

With these applications in mind, the MIT Rocket Team has developed a rocket capable of deploying a UAV designed to fold up for storage inside of it. Furthermore, the team has designed a flight mission that will simulate a search and rescue mission, while simultaneously completing the mission goals outlined in the NASA Science Mission Directorate payload option. During the flight mission, the UAV will be used to visually locate the landed rocket, while also gathering, transmitting, and storing all of the scientific data as mentioned in the SMD requirements. By completing both of these tasks, the MIT Rocket Team will prove the effectiveness of the flight system while performing the tasks for which it has been developed. To facilitate this mission, a simplified flight control interface is being developed that will translate the complex task of UAV flight into simple “point-and-click” commands. To make this possible a low cost, off the shelf autopilot system will take in GPS coordinates in real time from the flight control system on the ground and control the flight of the UAV between chosen waypoints.

All preliminary design has been completed, and team is now moving into the fabrication and testing stage. With a goal of creating a strong and light launch vehicle, the MIT Rocket Team has chosen a four-ply carbon fiber layup as the main material for a large percentage of the rocket. The MIT Rocket Team has great skill working with composite materials, and for the past five years all rockets produced by the team have been fabricated out of fiberglass and/or carbon fiber. The development of a UAV however is a new task for the MIT Rocket Team and the added complexities of designing an aircraft that could fit within a 6 in body tube has been no easy task. However, the Team has developed a simple and unique method to fold the wings and control surfaces of the UAV allowing for a sufficiently large craft to reliably perform all necessary tasks. In the following months the MIT Rocket Team will transition from design work to testing and fabrication. With this transition, the team is committed to completing all tasks necessary to stay on the competition schedule. To help facilitate this task, the team has developed detailed schedule, and planning meetings are held on a weekly basis to ensure that all tasks are being completed on schedule. With a dedicated team, an exciting project, and the support of the greater MIT community, the MIT Rocket Team is more than ready to enter its first USLI competition.

APPENDIX I: MASTER EQUIPMENT LIST

System Summary

System Mass (kg) Cost (USD)

Propulsion 5.56 562.99

Airframe-Body 5.26 581.32

Airframe-Fairing 1.01 27.00

Avionics/Comm 0.58 1,004.94

Payload Support Equipment 1.80 173.00

Recovery 2.02 480.64

SUBTOTAL 16.23 2829.89

Propulsion 1.15 190.00

Airframe 0.96 370.00

ACS 0.16 70.00

Avionics 0.21 668.73

Payload 0.20 757.25

Recovery 0.00 50.00

SUBTOTAL 2.68 2105.98

Ground Station N/A 5,644.85

Testing N/A 2,000.00

Spares N/A 4,000.00

Team Support N/A 4,260.00

TOTALS 18.91 20,840.72

Support

Rocket

UAV

Master Equipment List Updated on 11/16/10

ID # Subsystem Item name Usage Certainty Description (Vendor, part #, etc.) Cost/ Item

Mass

kg/Item # Items Location Total Cost ($)

Cost

Margin

Margined

Cost

Total Mass

(kg)

Mass

Measured

Mass

Margin

Margined

Mass Bought Built On-Hand Tested Integrated Date Updated Person who updated

R01-01 Propulsion Motor Cessasroni L1115-P $247 3.491 1 247.00 247.00 3.491 0% 3.49

R01-02 Casing Pro75-4G $305 1.97 1 305.00 305.00 1.97 0% 1.97

R01-03 Igniter Wildman 89894 $11 0.1 1 10.99 10.99 0.1 0% 0.10

R01-04 1 0.00 0.00 0 0% 0.00

R01-05 1 0.00 0.00 0 0% 0.00

R01-06 1 0.00 0.00 0 0% 0.00

Add rows above this row, do not delete this row

Total 562.99 20% 562.99 5.561 20% 5.56

Allocation 600.00 20% 720.00 5.625 20% 6.75

R02-01-01 Airframe-Body Stage Body: lower $82 1.22 1 82.00 82.00 1.22 1.22

R02-01-02 Stage Body: upper $82 1.27 1 82.00 82.00 1.27 1.27

R02-02 Bulkhead $10 0.15 1 10.00 10.00 0.15 0.15

R02-03 Casing Spacing Ring $10 0.11 3 30.00 30.00 0.33 0.33

R02-04 Rail Guide $5 0.05 3 15.00 15.00 0.15 0.15

R02-05 Epoxy $2 0.02 20 40.00 40.00 0.4 0.40

R02-06 Fin $5 0.08 4 20.00 20.00 0.32 0.32

R02-07-01 Coupler: upper $10 0.17 1 10.00 10.00 0.17 0.17

R02-07-02 Coupler: lower $10 0.08 1 10.00 10.00 0.08 0.08

R02-08 Avionics Tube $20 0.05 1 20.00 20.00 0.05 0.05

R02-09 Avionics Plate $30 0.15 2 60.00 60.00 0.3 0.30

R02-10 Eye-Bolt 3067T71 $4 0.04 4 17.32 17.32 0.16 0.16

R02-11-01 NoseSep-Outer $10 0.08 1 10.00 10.00 0.08 0.08

R02-11-02 NoseSep-Inner $10 0.07 1 10.00 10.00 0.07 0.07

R02-12 Payload Support Bulkhead $130 0.30 1 130.00 130.00 0.3 0.30

R02-13 Motor Mount Tube $15 0.08 1 15.00 15.00 0.08 0.08

R02-14 Motor Retention Plate $10 0.05 1 10.00 10.00 0.05 0.05

R02-15 Avionics Bolt Doubler $10 0.08 1 10.00 10.00 0.08 0.08

R02-16 Inserts 91732A355 $0 0.02 8 3.45 3.45 0.16 0.16

R02-17 Eye-Bolt Inserts 94165A435 $2 0.02 4 7.94 7.94 0.08 0.08Add rows above this row, do not delete this rowTotal 581.32 20% 581.32 5.50 20% 5.26Allocation 500.00 20% 600.00 5.60 20% 6.72

R03-01 Airframe-Fairing Fairing Body $27 1.01 1 27.00 27.00 1.01 1.01

Add rows above this row, do not delete this row

Total 27.00 20% 27.00 1.01 20% 1.01

Allocation 100.00 20% 120.00 1.25 20% 1.50

R04-01 Avionics Flight Computer ARTS2 $189.99 0.100 1 189.99 189.99 0.1 0.10

R04-02 Altimeter Perfect Flight MAWD $99.95 0.050 1 99.95 99.95 0.05 0.05

R04-03 Battery 9v Battery $5.00 0.050 3 15.00 15.00 0.15 0.15

R04-04 Transmitter ARTS2 Transmitter $450.00 0.050 1 450.00 450.00 0.05 0.05

R04-05 Antenna $20.00 0.050 0 0.00 0.00 0 0.00

R04-06 Tracking Transmitter

AT-2B ELT Transmitter: Communications

Specialists $105.00 0.030 2 210.00 210.00 0.06 0.06

R04-07 Avionics Plate $10.00 0.050 1 10.00 10.00 0.05 0.05

R04-08 Avionics L Bracket $5.00 0.025 4 20.00 20.00 0.1 0.10

R04-09 Kapton Tape $10.00 0.020 1 10.00 10.00 0.02 0.02

Add rows above this row, do not delete this row

Total 1,004.94 20% 1,004.94 0.58 20% 0.58

Allocation 1,000.00 20% 1,200.00 0.6 20% 0.72

R05-01 Payload Support Equipment Sabot Half

2 LB density urethane foam

(http://www.uscomposites.com/foam.ht

ml) $20.50 0.600 2 41.00 41.00 1.2 1.20

R05-02 Hard Point Half $20.00 0.100 4 80.00 80.00 0.4 0.40

R05-03 Stringer $13.00 0.050 4 52.00 52.00 0.2 0.20

Add rows above this row, do not delete this row

Total 173.00 20% 173.00 1.8 20% 1.80

Allocation 200.00 20% 240.00 1.5 20% 1.80

Master Equipment List Updated on 09/03/10

ID # Subsystem Item name

Usage

Certainty Description (Vendor, part #, etc.) Cost/ Item

Mass

kg/Item # Items Location Total Cost ($)

Cost

Margin

Margined

Cost

Total Mass

(kg)

Mass

Measured

Mass

Margin

Margined

Mass Bought Built On-Hand Tested Integrated Date Updated Person who updated

U01-01 Propulsion Motor AXI4120-18 $50 0.32 1 50.00 50.00 0.32 0% 0.32

U01-02 Foldable Prop CAN Folding Prop 13x8 cm (Graupner) $10 0.05 1 10.00 10.00 0.05 0% 0.05

U01-03 Speed Controller $50 0.1 1 50.00 50.00 0.1 0% 0.10

U01-04 Battery Turnigy 5000mAh 5S 25C LipoPack (http://www.hobbycity.com/hobbycity/store/uh_viewItem.asp?idProduct=9175)$80 0.677 1 80.00 80.00 0.677 0% 0.68

U01-05 0.00 0.00 0 0% 0.00

U01-06 0.00 0.00 0 0% 0.00

U01-07 0.00 0.00 0 0% 0.00

U01-08 0.00 0.00 0 0% 0.00

Add rows above this row, do not delete this row

Total 190.00 20% 190.00 1.147 20% 1.15

Allocation 400.00 20% 480.00 1 20% 1.20

U02-01 Airframe Fuselage $100 0.50 1 100.00 100.00 0.496 0.50

U02-02 Wing $100 0.41 1 100.00 100.00 0.408 0.41

U02-03 Wing Rotation Mechanism $20 1 20.00 20.00 0 0.00

U02-04 Motor Bulkhead $10 1 10.00 10.00 0 0.00

U02-05 Tail $20 0.06 1 20.00 20.00 0.059 0.06

U02-07 Various Mounts $20 4 80.00 80.00 0 0.00

U02-09 Elevator $20 1 20.00 20.00 0 0.00

U02-10 Rudder $20 1 20.00 20.00 0 0.00

U02-11Add rows above this row, do not delete this rowTotal 6.35 370.00 20% 370.00 0.96 20% 0.96Allocation 400.00 20% 480.00 2.50 20% 3.00

U03-01 ACS Servo $20 0.04 2 40.00 40.00 0.08 0.08

U03-02 Servo Wire $10 0.02 2 20.00 20.00 0.04 0.04

U03-03 Flight Surface Horn $5 0.02 2 10.00 10.00 0.04 0.04

U03-04 0.00 0.00 0 0.00

Add rows above this row, do not delete this row

Total 70.00 20% 70.00 0.16 20% 0.16

Allocation 100.00 20% 120.00 0.5 20% 0.60

U04-01 Avionics/Comm RC Receiver Backup hand RC control $30.00 0.030 1 30.00 30.00 0.03 0.03

U04-02 Flight Computer ArduPilot Mega $59.95 1 59.95 59.95 0 0.00

U04-03 Video Antenna XBEE 900 Antenna $42.95 1 42.95 42.95 0 0.00

U04-04 Telemetry Antenna 99mhz Duck Antenna $7.95 1 7.95 7.95 0 0.00

U04-05 Video Transmitter Aerial Video System $199.00 1 199.00 199.00 0 0.00

U04-06 GPS Receiver Module Media Tek GPS $38.95 1 38.95 38.95 0 0.00

U04-07 Tracking Beacon $106.00 0.030 1 106.00 106.00 0.03 0.03

U04-08 Battery $20.00 0.150 1 20.00 20.00 0.15 0.15

U04-09 IMU-Shield ArduPilot Mega IMU Shield/OilPan $159.95 1 159.95 159.95 0 0.00

U04-10 Connectors 3x8 Right Angle Pin Headers $1.99 2 3.98 3.98 0 0.00

Add rows above this row, do not delete this row

Total 668.73 20% 668.73 0.21 20% 0.21

Allocation 700.00 20% 1,000.00 1 20% 1.20

U05-01 Payload Camera $200.00 0.150 1 200.00 200.00 0.15 0.15

U05-02 Camera Actuator $100.00 0.050 1 100.00 100.00 0.05 0.05

U05-03 Sensor X Radio Beacon $400.00 0 0.00 0.00 0 0.00

U05-04 Humidity/temp/solar HTS3-R1-A $61.75 2 123.50 123.50 0 0.00

U05-05 UV Index Meter UVI2-R1-A $40.00 2 80.00 80.00 0 0.00

U05-06 Pressure Sensor SCP1000 Breakout $34.95 2 69.90 69.90 0 0.00

U05-07 SD Card Writer

Breakout Board for DOSonCHIP FAT16

FAT32 uSD Module $44.95 1 44.95 44.95 0 0.00

U05-08 Backup board Arduino Uno $29.95 1 29.95 29.95 0 0.00

U05-09 Still Camera

Canon PowerShot A470 7.1 MP Digital

Camera $66.00 1 66.00 66.00 0 0.00

U05-10 Telemetry Board XBee Pro 900 Wire Antenna $42.95 1 42.95 42.95 0 0.00

Add rows above this row, do not delete this row

Total 0.68 757.25 20% 757.25 0.2 20% 0.20

Allocation 800.00 20% 960.00 1.25 20% 1.50

U06-01 Recovery Skid $10.00 2 20.00 20.00 0 0.00

U06-02 Skid Spport $10.00 2 20.00 20.00 0 0.00

U06-03 Tail Stub $10.00 1 10.00 10.00 0 0.00

U06-04 0.00 0.00 0 0.00

Add rows above this row, do not delete this row

Total 50.00 20% 50.00 0 20% 0.00

Allocation 100.00 20% 120.00 0.25 20% 0.30

Total 2,105.98 2,105.98 2.68 2.68

Allocation 2,500.00 3,160.00 6.50 7.80

ID # Subsystem Item name Description (Vendor, part #, etc.) Cost/ Item

Mass

lb/Item # Items Location Total Cost ($)

Cost

Margin

Margined

Cost

Total Mass

(kg)

Mass

Measured

Mass

Margin

Margined

Mass Bought Built On-Hand Tested Integrated Date Updated Person who updated

R06-01 Ground Station Tracking Receiver PR-100: Communications Specialists $249.95 1 249.95 249.95 0 0% 0.00

R06-02 Video Modem $800.00 1 800.00 800.00 0 0% 0.00

R06-03 Receiving Antenna $200.00 1 200.00 200.00 0 0% 0.00

R06-04 Ground Laptop $1,000.00 1 1,000.00 1,000.00 0 0% 0.00

Power Station $400.00 1 400.00 400.00 0 0% 0.00

Add rows above this row, do not delete this row

Total 2,649.95 40% 2,649.95 0 40% 0.00

Allocation 3,000.00 40% 4,200.00 1.6 40% 2.24

R07-01 Testing Testing Hardware Budget 1 1,000.00 1,000.00 0 0% 0.00

R07-02 1 0.00 0.00 0 0% 0.00

R07-03 1 0.00 0.00 0 0% 0.00

R07-04 1 0.00 0.00 0 0% 0.00

R07-05 1 0.00 0.00 0 0% 0.00

R07-06

Add rows above this row, do not delete this row

Total 1,000.00 40% 1,000.00 0 40% 0.00

Allocation 1,000.00 40% 1,400.00 0 40% 0.00

R08-01 Spares Spare Parts Budget 1 2,000.00 2,000.00 0 0% 0.00

R08-02 1 0.00 0.00 0 0% 0.00

R08-03 1 0.00 0.00 0 0% 0.00

R08-04 1 0.00 0.00 0 0% 0.00

1 0.00 0.00 0 0% 0.00

Add rows above this row, do not delete this row

Total 2,000.00 40% 2,000.00 0 40% 0.00

Allocation 2,000.00 40% 2,800.00 1.6 40% 2.24

R09-01 Team Support Travel to Competition $300.00 6 1,800.00 1,800.00 0 0% 0.00

R09-02 Lodging @ Competition $80.00 12 960.00 960.00 0 0% 0.00

R09-03 Shipping $500.00 1 500.00 500.00 0 0% 0.00

R09-04 Team Building $1,000.00 1 1,000.00 1,000.00 0 0% 0.00

1 0.00 0.00 0 0% 0.00

Add rows above this row, do not delete this row

Total 4,260.00 40% 4,260.00 0 40% 0.00

Allocation 5,000.00 40% 5,000.00 0 40% 0.00

Total 9,909.95 9,909.95 0.00 0.00

Allocation 11,000.00 13,400.00 3.20 4.48

ID # Subsystem Item name Description (Vendor, part #, etc.) Cost/ Item

Mass

lb/Item # Items Location Total Cost ($)

Cost

Margin

Margined

Cost

Total Mass

(kg)

Mass

Measured

Mass

Margin

Margined

Mass Bought Built On-Hand Tested Integrated Date Updated Person who updated

U06-01 Ground Station Tracking Receiver Communications Specialists PR-100 $249.95 1 249.95 249.95 0 0% 0.00

U06-02 Video Modem $800.00 1 800.00 800.00 0 0% 0.00

U06-03 Receiving Antenna $100.00 5 500.00 500.00 0 0% 0.00

U06-04 Ground Laptop $1,000.00 1 1,000.00 1,000.00 0 0% 0.00

U06-05 Programming etc cable FTDI Cable $17.95 1 17.95

U06-06 Ground station Antenna Antenna 900MHz RP-SMA 3.1dBi $10.60 1 10.60

U06-07 Ground station transmitter board XtreamBee Board (No XBee included) $24.95 1 24.95

U06-08 Ground station transmitter XBee Pro 900 RPSMA $44.95 1 44.95 44.95 0

Power Station $400.00 1 400.00 400.00 0 0% 0.00

Add rows above this row, do not delete this row

Total 3,048.40 40% 2,994.90 0 40% 0.00

Allocation 3,000.00 40% 4,200.00 1.6 40% 2.24

U07-01 Testing Testing Hardware Budget 1 1,000.00 1,000.00 0 0.00

U07-02 1 0.00 0.00 0 0.00

U07-03 1 0.00 0.00 0 0.00

U07-04 1 0.00 0.00 0 0.00

U07-05 1 0.00 0.00 0 0.00

U07-06

Add rows above this row, do not delete this row

Total 1,000.00 40% 1,000.00 0 40% 0.00

Allocation 1,000.00 40% 1,400.00 0 40% 0.00

U08-01 Spares Spares Budget 1 2,000.00 2,000.00 0 0% 0.00

U08-02 1 0.00 0.00 0 0% 0.00

U08-03 1 0.00 0.00 0 0% 0.00

U08-04 1 0.00 0.00 0 0% 0.00

1 0.00 0.00 0 0% 0.00

Add rows above this row, do not delete this row

Total 2,000.00 40% 2,000.00 0 40% 0.00

Allocation 2,000.00 40% 2,800.00 1.6 40% 2.24

Total 6,048.40 5,994.90 0.00 0.00

Allocation 6,000.00 8,400.00 3.20 4.48

Master Equipment List Updated on 09/20/09

ID # Subsystem Item name Description (Vendor, part #, etc.) Vendor Cost/ Item # Items Location Total Cost ($)

Cost

Margin

Margined

Cost Bought Used Date Updated Person who updated

A-001 Tools Gloves 12 pair latex Raka Inc 4.75 4 19.00 19.00

A-002 Tools Dust Masks (25 pair) Raka Inc 30$ 1 29.75 29.75

A-003 Tools Mixing Pots (16 oz) Raka Inc 1$ 5 3.75 3.75

A-004 Tools Phenolic Tubing PML 12$ 5 60.25 60.25

A-005 Tools Aluminum Stock (for nosecone) 200$ 2 400.00 400.00

A-006 Tools 0.00 0.00

Add rows above this row, do not delete this row

Total 512.75 512.75

Allocation 1,000.00 1,000.00

B-001 Consumables Carbon Fiber 3k, 2x2 twill; 5.7 oz x50" (unit=yd) Raka Inc $44 30 1,312.50 1,312.50

B-002 Consumables Fiberglass 2.3 oz x 56" (unit=yd) Raka Inc $4 30 112.50 112.50

B-003 Consumables Epoxy Resin Quart 2032 AircraftSpruce $25 8 203.20 203.20

B-004 Consumables Epoxy Hardener Quart 3665 AircraftSpruce $25 2 50.80 50.80

B-005 Consumables Mylar $100 1 100.00 100.00

B-006 Consumables Vacuum Bag Release 01-14835 AircraftSpruce $5 20 95.00 95.00

B-007 Consumables Strechlon 01-01080 AircraftSpruce $3 20 62.80 62.80

B-008 Consumables Sealant Tape M20-8731 Fiberglass $7 5 35.40 35.40

B-009 Consumables Vacuum Cups M43-0735 Fiberglass $15 2 29.08 29.08

B-010 Consumables Vacuum Tubing M43-0854 Fiberglass $12 2 24.98 24.98

B-011 Consumables High Temp Wax $13 2 25.50 25.50

B-012 Consumables Polycarbonate 0.125" thick $100 2 200.00 200.00

B-013 Consumables Pyrogen Kit ML-KIT PML $31 1 30.95 30.95

B-014 Consumables Copper Leads for Igniters ML-24 (x12) PML $13 5 62.75 62.75

B-015 Consumables TSLOTS for Test Stand Automationforless $200 1 200.00 200.00

B-016 Consumables Angle Bracket (1"x1") $150 1 150.00 150.00

B-017 Consumables Breather/Bleeder 01-14810 AircraftSpruce $2 20 36.00 36.00

B-018 Consumables Release2 M13-4309 Fiberglass $1 20 22.80 22.80

Add rows above this row, do not delete this rowTotal 2,754.26 2,754.26Allocation 4,000.00 4,000.00

2

APPENDIX II: SCHEDULE

ID Task Name

1 Proposal

2 Structural Test Fabrication

3 Structural Design

4 Avionics Design Completed

5 Recovery Design

6 Deployment Mechanism

7 Pre-PDR Design Freeze

8 Risk Assessment

9 Inital Drawing Creation

10 Integration/Launch Procedure Development

11 Sabot Design

12 PDR

13 Splash Education Outreach

14 Initial Structural Testing

15 Ground Station Electronics Development

16 Trajectory Model Development

17 Trajectory Model Verification

18 Search Pattern Model Development

19 Search Pattern Model Verification

20 UAV to Ground Station Model Updates

21 Trajectory Model Updates

22 Operations Update

23 Deployment Testing

24 Unfolding Testing

25 Prototype Fabrication

26 Pre-CDR Design Freeze

27 Drawing Updates

28 CDR

29 Final Unfolding and Control Surface Testing

30 Final Deployment Testing

31 Fab Update for Test Launch

32 Full-Scale Test Launch

33 Ops Procedures Update

34 Pre-FRR Design Freeze

35 FRR

36 Flight Vehicle Fabrication

37 Finalization of Ops Procedures

38 Ship Flight Vehicle

11/19

1/24

3/21

19 26 3 10 17 24 31 7 14 21 28 5 12 19 26 2 9 16 23 30 6 13 20 27 6 13 20 27 3 10 17 24Oct '10 Nov '10 Dec '10 Jan '11 Feb '11 Mar '11 Apr '11

Task

Split

Progress

Milestone

Summary

Project Summary

External Tasks

External Milestone

Deadline

Page 1

Project: Schedule Sept. 29, 2010Date: Fri 11/19/10

ID Task Name

39 Launch 4/1619 26 3 10 17 24 31 7 14 21 28 5 12 19 26 2 9 16 23 30 6 13 20 27 6 13 20 27 3 10 17 24

Oct '10 Nov '10 Dec '10 Jan '11 Feb '11 Mar '11 Apr '11

Task

Split

Progress

Milestone

Summary

Project Summary

External Tasks

External Milestone

Deadline

Page 2

Project: Schedule Sept. 29, 2010Date: Fri 11/19/10

3

APPENDIX III: SOLIDWORKS DRAWINGS

5.787

4X 0.144 THRU

27.000

1.63

6.16

3

R120.0(TANGENT OGIVE PROFILE)

NOSE CONE

FINISH: NONE

MATERIAL: LAMINATE AS SPEC'D BELOW

2

1

3 DOUBLER REGION; DROPOFF IN AT LEAST .50"

1

3

PLY # MATERIAL THICKNESS (IN)

ORIENTATION (DEG) NOTES

1 CARBON FIBER 11 OZ WEAVE .015 0 TOOL SIDE2 CARBON FIBER 11 OZ WEAVE .015 03 CARBON FIBER 11 OZ WEAVE .015 04 CARBON FIBER 11 OZ WEAVE .015 05 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY6 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY7 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY8 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY9 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY10 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY11 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY12 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY

D

C

B

AA

B

C

D

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

01

SolidWorks Student Edition. For Academic Use Only.

0.755.75

10.00

12.63

3

0.31

FIN LAMINATE

FINISH: NONE

MATERIAL: LAMINATE AS SPEC'D BELOW

2

1

3 NOTE THAT CARBON FIBER LAMINATEPLIES ONLY EXTEND IN THIS REGION

1

PLY # MATERIAL THICKNESS (IN)

ORIENTATION (DEG) NOTES

1 CARBON FIBER 11 OZ WEAVE .015 02 PLYWOOD 3/16 03 CARBON FIBER 11 OZ WEAVE .015 0

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

01

SolidWorks Student Edition. For Academic Use Only.

6.161.110.00

32.9

46.5

1.51.5

33.500.88

4X 0.144 THRU 4X 0.144 THRU

48.00

3 3

BODY TUBE: SEGMENT1

FINISH: NONE

MATERIAL: LAMINATE AS SPEC'D BELOW

2

1

3 DOUBLER REGION; DROPOFF IN AT LEAST .50"

1

3

PLY # MATERIAL THICKNESS (IN)

ORIENTATION (DEG) NOTES

1 CARBON FIBER 11 OZ WEAVE .015 0 TOOL SIDE2 CARBON FIBER 11 OZ WEAVE .015 03 CARBON FIBER 11 OZ WEAVE .015 04 CARBON FIBER 11 OZ WEAVE .015 05 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY6 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY7 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY8 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY9 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY10 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY11 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY12 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

PROPRIETARY AND CONFIDENTIAL

NEXT ASSY USED ON

APPLICATION

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

01

SolidWorks Student Edition. For Academic Use Only.

6.160.63

1.5

48.550.00

1.5

4X 0.144 THRU

0.63

4X 0.144 THRU

AA3

3

SECTION A-A SCALE 1 : 5

BODY TUBE: SEGMENT2

FINISH: NONE

MATERIAL: LAMINATE AS SPEC'D BELOW

2

1

3 DOUBLER REGION; DROPOFF IN AT LEAST .50"

1

3

PLY # MATERIAL THICKNESS (IN)

ORIENTATION (DEG) NOTES

1 CARBON FIBER 11 OZ WEAVE .015 0 TOOL SIDE2 CARBON FIBER 11 OZ WEAVE .015 03 CARBON FIBER 11 OZ WEAVE .015 04 CARBON FIBER 11 OZ WEAVE .015 05 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY6 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY7 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY8 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY9 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY10 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY11 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY12 CARBON FIBER 11 OZ WEAVE .015 0 DOUBLER ONLY

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

PROPRIETARY AND CONFIDENTIAL

NEXT ASSY USED ON

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

01

SolidWorks Student Edition. For Academic Use Only.

.125 STK

.125 STK R.125 MINA

B .50

4.0

C

.75

2x .170

.75 2.50

2x .25

L Bracket

0.02 B C0.02 A B C

0.005 M B C

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

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NEXT ASSY USED ON

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

1

2

MATERIAL: AL 6061-T6

FINISH: NONE

3 PROFILE DIMENSIONS ARE REFERENCE ONLYCUT FILE SERVES AS PROFILE MASTER

4 UNLESS OTHERWISE SPECIFIED, PROFILE TOLERANCES ARE SHEETDEFAULT DIMENSIONS AND

01

SolidWorks Student Edition. For Academic Use Only.

5.50

.50

.5 2.0

6.155 STK

6.007 STK

AVIONICS TUBE

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

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NEXT ASSY USED ON

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DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.05ANGULAR: MACH/BEND 0.1ONE PLACE DECIMAL 0.1TWO PLACE DECIMAL 0.02THREE PLACE DECIMAL 0.005

INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

1

2

MATERIAL: PHENOLIC

FINISH: NONE

01

SolidWorks Student Edition. For Academic Use Only.

2X R0.125 MIN

0.380.19

1.50

3.80

R3.05

HARD POINT

FINISH: NONE

MATERIAL: DELRIN 2700

2

1

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

PROPRIETARY AND CONFIDENTIAL

NEXT ASSY USED ON

APPLICATION

DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.05ANGULAR: MACH/BEND 0.1ONE PLACE DECIMAL 0.1TWO PLACE DECIMAL 0.02THREE PLACE DECIMAL 0.005

INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

01

SolidWorks Student Edition. For Academic Use Only.

2.97 STK

3.08 STK

26.00

MOTOR TUBE

FINISH: NONE

MATERIAL: PHENOLIC TUBE

2

1

D

C

B

AA

B

C

D

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THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

01

SolidWorks Student Edition. For Academic Use Only.

3

2.5

6.0 47.0 3.05

3 INTERIOR MOLDED TO SHAPEOF UAV

SABOT

D

C

B

AA

B

C

D

12345678

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THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

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1

2

NOTES:

1

2

MATERIAL: FOAM

FINISH: NONE

01

SolidWorks Student Edition. For Academic Use Only.

1.000.75

B

BA

6.155

5.16

1.75

0.50 THRU

1/4-20 UNC THRU

B

C

0.38R0.25

SECTION B-B

4x 6-32 UNC THRU

P/L Support Bulkhead

FINISH: NONE

MATERIAL: NYLON

2

10.005 M A B C

0.02 M A B C

0.01 M A B C

D

C

B

AA

B

C

D

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

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CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

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UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

01

SolidWorks Student Edition. For Academic Use Only.

.125 STK

A

5.00

5.00

4x R.25 MIN

B

C0.02 B C0.02 A B C

D

C

B

AA

B

C

D

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THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

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DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.05ANGULAR: MACH/BEND 0.1ONE PLACE DECIMAL 0.1TWO PLACE DECIMAL 0.02THREE PLACE DECIMAL 0.005

INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

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MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

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UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

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DO NOT SCALE DRAWING

1

2

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1

2

MATERIAL: POLYCARBONATE

FINISH: NONE

3 PROFILE DIMENSIONS ARE REFERENCE ONLYCUT FILE SERVES AS PROFILE MASTER

4 UNLESS OTHERWISE SPECIFIED, PROFILE TOLERANCES ARE SHEETDEFAULT DIMENSIONS AND

01

SolidWorks Student Edition. For Academic Use Only.

.25 STK

6.007

.279 X 100°4x .150 THRU

4x 1.25

4x .56

BOTTOM AVIONICS PLATE

D

C

B

AA

B

C

D

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8 7 6 5 4 3 2 1

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

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DATENAME

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MITRT_Standard

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1

2

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1

2

MATERIAL: AL 6061-T6

FINISH: NONE

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SolidWorks Student Edition. For Academic Use Only.

.25 STK

6.007

.279 X 100°4x .150 THRU

4x 1.25

4x .56

1.75

.50

AVIONICS TOP PLATE

D

C

B

AA

B

C

D

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THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

1

2

MATERIAL: AL 6061-T6

FINISH: NONE

01

SolidWorks Student Edition. For Academic Use Only.

0.50 STKA

6.16

3.08

B

0.50 STKA

3.08

R3.08

4X 0.20

4X 2.39

B

CENTERING RINGS

UNLESS OTHERWISE SPECIFIED, PROFILE TOLERANCES ARE SHEETDEFAULT DIMENSIONS AND

4

PROFILE DIMENSIONS ARE REFERENCE ONLYCUT FILE SERVES AS PROFILE MASTER

3

FINISH: NONE

MATERIAL: PLYWOOD

2

1

SINGLE-MOTOR, SLOTTED CONFIGURATIONSINGLE-MOTOR, UNSLOTTED CONFIGURATION

0.02 B0.02 A B

D

C

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THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

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INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

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ENG APPR.

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Q.A.

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DATENAME

TITLE:

SIZE

BDWG. NO. REV

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SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

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SolidWorks Student Edition. For Academic Use Only.

6.273

6.155

0.19

0.38

A

2X 2.38

2X 0.219 THRUB

C

0.50A

6.155B

MOUNTING RINGS

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4

PROFILE DIMENSIONS ARE REFERENCE ONLYCUT FILE SERVES AS PROFILE MASTER

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PROPULSION BULKHEADREAR MOUNTING RING

0.02 B C0.02 A B C

0.005 M B C

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THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

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DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.05ANGULAR: MACH/BEND 0.1ONE PLACE DECIMAL 0.1TWO PLACE DECIMAL 0.02THREE PLACE DECIMAL 0.005

INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

01

SolidWorks Student Edition. For Academic Use Only.

0.031 STKA

3.00

R1.88

2X 2.38

2X R0.38

2X 0.170 THRU

B

C

RETENTION PLATE

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4

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3

FINISH: NONE

MATERIAL: STAINLESS STEEL

2

1

0.02 B C0.02 A B C

0.005 M B C

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AA

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THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFTHE MITRT PROGRAM. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFTHE MITRT PROGRAM IS PROHIBITED.

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DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.05ANGULAR: MACH/BEND 0.1ONE PLACE DECIMAL 0.1TWO PLACE DECIMAL 0.02THREE PLACE DECIMAL 0.005

INTERPRET GEOMETRICTOLERANCING PER: ASME Y14.M-2009

MATERIAL

FINISH

DRAWN

CHECKED

ENG APPR.

MFG APPR.

Q.A.

COMMENTS:

DATENAME

TITLE:

SIZE

BDWG. NO. REV

WEIGHT: SCALE: NONE

UNLESS OTHERWISE SPECIFIED:

SHEET 1 OF 1

MITRT_Standard

DO NOT SCALE DRAWING

1

2

NOTES:

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SolidWorks Student Edition. For Academic Use Only.

4

APPENDIX IV: AVIONICS AND CONTROL ARCHITECTURE

Flight  Computer  Wiring  Diagram    

 

 

 

 

 

 

 

 

 

 

 

 

 

 GND  

Serial  3  

HTS3-R1-A Sensor  Board  DQ  GND  

Vdd  

UVI2-R1-A  Sensor  Board  DQ  GND  

Vdd  

+12V  D.C.  

R/C  Receiver   Aileron  

Elevator  

Throttle  

Yaw  

Autopilot  Control  

Aileron  Servo  

Elevator  Servo  

GPS  

ESC   Motor  

+12V  D.C.  

SCP1000  Breakout  

 DRDY  GND  

Vdd  

 

ArduPilot  

 Mega  Board  

Input  0  

Input  1  

Input  2  

Input  3  

Input  4  

Input  5  

Input  6  

Input  7  

TRIG  Output  4   Digital  Camera  Trigger  Servo  

Rudder  Servo  Output  3  

Output  2  

Output  1  

Output  0  

Serial  2  

OILPAN  shield  (IMU)  

XBee  900MHZ  Board  

Output  5  

Vcc  

Voltage  Regulator  +12V  D.C.  

 

IN   OUT  

Back-­‐Up  Data-­‐Logging  Board  Wiring  Diagram    

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

+12V  D.C.  

HTS3-R1-A Sensor  Board  DQ  GND  

Vdd  

UVI2-R1-A  Sensor  Board  DQ  GND  

Vdd  Arduino  Uno  Board  

  3V3  

12  

11  

10  

13  

GND  

 DOSonCHIP  FAT16  FAT32  uSD  

 4  Vdd  

7  DO  

3  DI  

2  CS  

5  CLK  

6  Vss  

4.7k  

4.7k  

4.7k  

10k  

10k  

10k  

Vin  

3  

5  

SCP1000  Breakout  

 DRDY  GND  

Vdd  4  TRIG  

Payload  Data  Flow  Diagram  

Flight  Computer    

Inertia  Measuring  Unit  

Oilpan  

GPS  Receiver  

GS407  U-­‐Blox5  

Position  

Velocity  

Position  

900MHz  Transmitter  

Xbee  Pro  900   Humidity,  Position,  Solar    UVI,  Temperature,  Pressure    

Humidity,  Position,  Solar    UVI,  Temperature,  Pressure  

Flight  Computer  

ArduPilot  Mega  

16Mb  Flash  Memory  

Internal  to  ArduPilot  Mega  

Humidity    UVI        Temperature    Solar  Pressure  Position  

UVI  Sensor  Board    UVI2-R1-A  

Humidity/  Temperature/  Solar  Board    HTS3-R1-A  

UVI      Temperature   Humidity      Temperature,  Solar  

Pressure  Sensor  Board  

SCP1000  Breakout    

Pressure  

Ancillary  Boards      

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

C-­‐MOS  Camera  

CM-­‐26P  

 

2.4GHz  Transmitter  

AVS-­‐2400-­‐1000-­‐KX171-­‐G2  

Video  Data    

Video  Data  

Humidity/  Temperature/  Solar  Board    HTS3-R1-A  

Back-­‐Up  Data-­‐loop  Board    Arduino  Uno  

Micro  SD  Card      Via  DOSonCHIP  FAT16  FAT32  uSD  Module    

UVI    Temperature  Humidity      Temperature,  Solar  

UVI  Sensor  Board    UVI2-R1-A  

Pressure  Sensor  Board    SCP1000  Breakout    

Pressure  

Humidity,  UVI        Temperature    Solar,  Pressure  

Flight  Computer  Operation  Flow  Diagram    

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

Deployment  Event  

Start  

Initialize  navigation  (GPS  and  IMU)  

Initialize  Sensors  

Check  command  uplink  

Stabilize  UAV  

Update  waypoint  list  

Received  new  waypoint?  

Yes  

No  

Correct  UAV  flight  path  

Stabilize  UAV  

Poll  sensors  for  data  

Transmit  sensor  data  

Log  sensor  data  

Set  mode:  ‘LOITER’  

Yes   ‘LAND’  command  received?  

No  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

   

‘CAPTURE’  command  received?  

Command  Cannon  A470  to  take  an  image  

Yes  

No  

Reached  waypoint?  No   Yes  

Finish  

Perform  landing  subroutine  

Transmit  logged  data  and  stills  to  ground  station  

Check  command  uplink  

‘CAPTURE’  command  received?  

Command  Cannon  A470  to  take  an  image  

Yes  

No  

Back-­‐Up  Data-­‐Logging  Operation  Flow  Diagram    

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

   

   

Start  

Finish  

Initialize  Sensors  

Poll  sensors  for  data  

Convert  sensor  data  to  usable  format  

Save  data  on  non-­‐volatile  memory  

Wait  1000ms  

UAV  Avionics  Master  Equipment  List  System   Part   Unit  Price   Units   Price   Description  

UAV  Flight  Computer  

ArduPilot  Mega   $59.95   1   $59.95   Main  Board  ArduPilot  Mega  IMU  Shield/OilPan   $159.95   1   $159.95   Navigation  Board  3x8  Right  Angle  Pin  Headers   $1.99   2   $3.98   Connectors  FTDI  Cable   $17.95   1   $17.95   Programming  etc  cable  Antenna  900MHz  RP-­‐SMA  3.1dBi   $10.60   1   $10.60   Ground  station  Antenna  XtreamBee  Board  (No  XBee  included)   $24.95   1   $24.95   Ground  station  transmitter  board  XBee  Pro  900  RPSMA   $44.95   1   $44.95   Ground  station  transmitter  XBee  Pro  900  Wire  Antenna   $42.95   1   $42.95   UAV  transmitter  GS407  U-­‐Blox5  GPS  4Hz   $87.90   1   $87.90   GPS  EM-­‐406/uBlox/MTK  Adapter  Cable  15  cm   $1.95   1   $1.95   GPS  cable  

SMD  Payload  

HTS3-­‐R1-­‐A   $61.75   2   $123.50   Humidity/temp/solar  UVI2-­‐R1-­‐A   $40.00   2   $80.00   UV  Index  Meter  SPC-­‐1000  Breakout   $34.95   2   $69.90   Pressure  Sensor  Breakout  Board  for  DOSonCHIP  FAT16  FAT32  uSD  Module   $44.95   1   $44.95   SD  Card  Writer  Arduino  Uno   $29.95   1   $29.95   Backup  board  Canon  PowerShot  A470  7.1  MP  Digital  Camera   $66.00   1   $66.00   Stills  Camera  

Video  Downlink  AVS-­‐2400-­‐1000-­‐KX171-­‐G2   $245.00   1   $245.00   Video  Streaming  CMOS  Camera  -­‐  640x480   $31.95   1   $31.95   Video  Camera  

    Total  Price   $1,146.38      

   

Ground  Station  Diagrams  

Primary  Console    

 

 

 

 

 

 

 

 

 

Altitude  Velocity                  Temperature  UVI  Pressure  Solar  

Land  Here  

Go  Here  

Capture  Still  

Secondary  Console  

   

 

 

 

 

 

 

5

APPENDIX V: MANUFACTURING PLAN

MIT, University Student Launch Initiative (USLI) Rocket Manufacturing Plan

Massachusetts Institute of Technology Rocket Team

University Student Launch Initiative (USLI)

Manufacturing Plan

Department of Aeronautics and Astronautics Massachusetts Institute of Technology, MA 02142

The publication of this material does not constitute approval by the MIT Rocket Team of the findings or conclusion herein. Wide distribution or announcement of this material shall not be made without the specific approval of the MIT Rocket Team. Distribution limited to MIT Rocket Team members, associated reviewers, and their contractors

Rocket Team University Student Launch Initiative Massachusetts Institute of Technology

Rev Date: 20100317

Manufacturing Plan, Revision 20101113 Use or disclosure of data contained on this sheet is subject to the restrictions on the title page of

this document.

Page 2 of 11

SIGNATURES ______________________________________________ Rocket Team President ______________________________________________ Rocket Team Manufacturing Plan Owner ______________________________________________ Payload Group Lead ______________________________________________ Rocket Structure Group Lead ______________________________________________ Safety Officer ______________________________________________ Advisor, MIT Rocket Team

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this document.

Page 3 of 11

Table of Contents

Purpose ................................................................................................................................ 6  Applicable Documents ........................................................................................................ 6  General Procedures and Standards ...................................................................................... 6  Specific Procedures and Nomenclature ............................................................................... 6  Manufacturing Description ................................................................................................. 7  

Rocket Structure .............................................................................................................. 8  Procedure ..................................................................................................................... 8  Tasking ........................................................................................................................ 9  Specifications .............................................................................................................. 9  

Payload .......................................................................................................................... 11  Procedure ................................................................................................................... 11  Tasking ...................................................................................................................... 11  Specifications ............................................................................................................ 11  

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Table of Figures

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Table of TablesNo table of figures entries found. In your document, select the words to include in the table of contents, and then on the Home tab, under Styles, click a heading style. Repeat for each heading that you want to include, and then insert the table of contents in your document. To manually create a table of contents, on the Document Elements tab, under Table of Contents, point to a style and then click the down arrow button. Click one of the styles under Manual Table of Contents, and then type the entries manually.

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TBRs/TBDs When numbers or interfaces are simply estimates, then they will be noted as To Be Reviewed (TBR). When numbers or interfaces are not known, then they will be noted as To Be Determined (TBD). Numbers and interfaces that are TBR/TBD are summarized in the table below: Section(s) Description

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Purpose The purpose of this document is to describe the specifications and methods by which parts of the rocket and payload will be manufactured. These components will then be integrated into a working vehicle as defined in the Integration Plan.

Applicable Documents

• Master Equipment List: command_media\uav_rocket-MEL.xls • Integration Plan: command_media\USLI-Integration_Plan.doc • Testing Plans: command_media\test_plans

General Procedures and Standards Manufacturing primarily takes place in the Rocket Team Lab facilities located in Building 17. Every member of the team has been trained in the proper handling and manufacturing of composite materials. Some manufacturing may require the use of the Department of Aeronautics and Astronautics Machine Shop. Senior team members have been trained in the use of the machine shop, both for safety and for proper machine use. The process of manufacturing each part begins after its schematic is completed and reviewed. Dimensions with tolerances are specified for each part, and measurements are taken after completion to ensure that these tolerances are met. Before construction of any part, the part is evaluated both individually and with respect to the whole rocket system to ensure that its construction and integration are feasible. Feasibility includes such aspects as tool access and the ability to reach bolt holes to insert bolts.

Specific Procedures and Nomenclature The following terms may be referenced throughout this document when describing commonly-used sets of materials or manufacturing procedures. • xx/xx Epoxy Mix: The standard epoxy mixture used for fabrication is Aeropoxy

2032 Resin with Aeropoxy 3665 hardener. The xx/xx denotes required masses of resin and hardener, respectively.

• Vacuum-bagging materials: The standard set of vacuum-bagging materials includes vacuum bag film, non-porous release film, polyester matting (“breather”), porous release film, peel-ply, Mylar, and sealant tape. The procedure to determine the sizing of each is as follows:

o Mylar: [part width + 4 in] x [tooling circumference + 1 in] o Peel-ply: [part width] x [tooling circumference + 1 in] o Porous release film: [part width + 1 in] x [tooling circumference + 2 in] o Matting: [part width] x [tooling circumference + 1 in]

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o Non-porous Release film: [part width + 1 in] x [tooling circumference + 2 in]

o Vacuum bag film: [part width + 6 in] x [tooling circumference + 8 in] o Sealant tape: 2x [vacuum bag film width], 2x [vacuum bag film length]

• Carbon fiber/fiberglass: [part width] x [(tooling circumference)*(ply count) + 2

in] • “Layup” procedure:

1. Wax mandrel 2. Wrap mandrel with Mylar 3. Apply peel-ply 4. Apply material (carbon fiber or fiberglass) with epoxy 5. Apply porous release film 6. Apply matting 7. Apply non-porous release film 8. Apply vacuum bag film; insert vacuum hose; seal with tape

Manufacturing Description Each part has one of two types of descriptions. If the part is student-constructed, it has a description of the procedure used to construct it and its CAD model. If the part was bought from a supplier, it lists the vendor, the part number, and the cost. The Procedure section lists all the parts and describes the process by which the part is constructed or bought. The Tasking section lists the students responsible for each part. The Specifications section contains the details about each part, including the dimensions (CAD model), cost, part number (if applicable) and material.

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Rocket Structure

Procedure The following procedure is based on the structural needs of the rocket. It involves the manufacturing and assembly of the rocket: I. Manufacture needed parts

a. Body Tubes i. Tooling: 6” O.D. x 50” mandrel ii. Materials: Carbon fiber, xx/xx epoxy mix, vacuum bagging

supplies iii. Procedure

1. Cut carbon fiber to required length 2. Layup material and vacuum bagging supplies 3. Place in oven, turn on vacuum, bake @ 200°F for 2 hrs

b. Nose Cone i. Tooling: nose cone mandrel ii. Materials: Carbon fiber, vacuum bagging supplies iii. Procedure

1. Cut fiberglass to required length 2. Layup material

c. Bulkheads i. Tooling: none ii. Materials: polycarbonate iii. Procedure

1. Waterjet profile 2. Mill final features (if necessary)

d. Fins i. Tooling: none ii. Materials: 3/16” thick balsa wood, carbon fiber, vacuum bagging

materials iii. Procedure

1. Cut profile in balsa with blade 2. Cut carbon fiber to required length 3. Layup material

e. Motor Mount i. Tooling: ii. Materials: iii. Procedure

1. Waterjet profile f. Avionics Bay Base Brackets

i. Tooling: none ii. Materials: polycarbonate iii. Procedure

1. Waterjet profile g. Avionics Bay Tube

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i. Tooling: none ii. Materials: Phenolic tube iii. Procedure

1. Cut tube to length 2. Cut pocket in tube

h. Avionics Damping Bracket i. Tooling: none ii. Materials: Aluminum angle stock iii. Procedure

1. Rough cut angle stock 2. Mill to final dimensions 3. Drill bolt holes

i. Motor Retention Plate i. Tooling: none ii. Materials: polycarbonate iii. Procedure

1. Waterjet profile

II. Perform quality control checks on each part by measuring its dimensions and comparing to drawings.

III. Assemble parts according to Rocket/Payload Integration Plan

Tasking The group lead, Ryan McLinko, will be responsible for the list of all the needed and manufactured parts. The following students are responsible for the creation and assembly of the sections mentioned above: I. Christian Valledor

a) Body tubes II. Jed Storey

a) Bulkheads b) Motor mount c) Motor retention plate

III. Ryan McLinko

a) Nose cone IV. Eric Peters

a) Avionics bay base brackets b) Avionics bay tube c) Avionics damping bracket

Specifications

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this document.

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The functionality of the structure imposes requirements on the vehicle, such as survival of aerodynamic loading during launch and deployment of the payload during descent. The following specifications are based on these requirements. See the ICDs for exact measurements Body Tubes:

Dimensions: 6” x 50” Material: 4-ply carbon fiber Cost: $$$

Bulkheads:

Dimensions: 6” outer diameter Material: ¼” thick polycarbonate Cost: $

Motor Mount:

Dimensions: 6” outer diameter Material: ¼” thick plywood Cost: $

Motor Retention:

Dimensions: 6” outer diameter Material: ¼” thick plywood Cost: $

Manufacturing Plan, Revision 20101113 Use or disclosure of data contained on this sheet is subject to the restrictions on the title page of

this document.

Page 11 of 11

Payload

Procedure

Tasking I. Jonathan Allen

a. Stuff b. More stuff

II. Jake a. Even more stuff

III. British a. Ones and zeros stuff

IV. Leo a. Assist with ones and zeros

Specifications Revision History Version Date Change By 0a 11/13/10 Created Eric Peters

6

APPENDIX VI: SAFETY DOCUMENTATION

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APPENDIX VII: MATERIAL SAFETY DATA SHEETS

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Material Safety Data SheetAcetone MSDS

Section 1: Chemical Product and Company Identification

Product Name: Acetone

Catalog Codes: SLA3502, SLA1645, SLA3151, SLA3808

CAS#: 67-64-1

RTECS: AL3150000

TSCA: TSCA 8(b) inventory: Acetone

CI#: Not applicable.

Synonym: 2-propanone; Dimethyl Ketone;Dimethylformaldehyde; Pyroacetic Acid

Chemical Name: Acetone

Chemical Formula: C3-H6-O

Contact Information:Sciencelab.com, Inc.14025 Smith Rd.Houston, Texas 77396US Sales: 1-800-901-7247International Sales: 1-281-441-4400Order Online: ScienceLab.com

CHEMTREC (24HR Emergency Telephone), call:1-800-424-9300

International CHEMTREC, call: 1-703-527-3887

For non-emergency assistance, call: 1-281-441-4400

Section 2: Composition and Information on IngredientsComposition:

Name CAS # % by Weight

Acetone 67-64-1 100

Toxicological Data on Ingredients: Acetone: ORAL (LD50): Acute: 5800 mg/kg [Rat]. 3000 mg/kg [Mouse]. 5340 mg/kg[Rabbit]. VAPOR (LC50): Acute: 50100 mg/m 8 hours [Rat]. 44000 mg/m 4 hours [Mouse].

Section 3: Hazards Identification

Potential Acute Health Effects:Hazardous in case of skin contact (irritant), of eye contact (irritant), of ingestion, of inhalation. Slightly hazardous in case ofskin contact (permeator).

Potential Chronic Health Effects:CARCINOGENIC EFFECTS: A4 (Not classifiable for human or animal.) by ACGIH. MUTAGENIC EFFECTS: Not available.TERATOGENIC EFFECTS: Not available. DEVELOPMENTAL TOXICITY: Classified Reproductive system/toxin/female,Reproductive system/toxin/male [SUSPECTED]. The substance is toxic to central nervous system (CNS). The substance maybe toxic to kidneys, the reproductive system, liver, skin. Repeated or prolonged exposure to the substance can produce targetorgans damage.

Section 4: First Aid Measures

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Eye Contact:Check for and remove any contact lenses. Immediately flush eyes with running water for at least 15 minutes, keeping eyelidsopen. Cold water may be used. Get medical attention.

Skin Contact:In case of contact, immediately flush skin with plenty of water. Cover the irritated skin with an emollient. Remove contaminatedclothing and shoes. Cold water may be used.Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medicalattention.

Serious Skin Contact:Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream. Seek medical attention.

Inhalation:If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medicalattention if symptoms appear.

Serious Inhalation:Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar, tie, belt or waistband. Ifbreathing is difficult, administer oxygen. If the victim is not breathing, perform mouth-to-mouth resuscitation. Seek medicalattention.

Ingestion:Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconsciousperson. Loosen tight clothing such as a collar, tie, belt or waistband. Get medical attention if symptoms appear.

Serious Ingestion: Not available.

Section 5: Fire and Explosion Data

Flammability of the Product: Flammable.

Auto-Ignition Temperature: 465°C (869°F)

Flash Points: CLOSED CUP: -20°C (-4°F). OPEN CUP: -9°C (15.8°F) (Cleveland).

Flammable Limits: LOWER: 2.6% UPPER: 12.8%

Products of Combustion: These products are carbon oxides (CO, CO2).

Fire Hazards in Presence of Various Substances: Highly flammable in presence of open flames and sparks, of heat.

Explosion Hazards in Presence of Various Substances:Risks of explosion of the product in presence of mechanical impact: Not available. Slightly explosive in presence of openflames and sparks, of oxidizing materials, of acids.

Fire Fighting Media and Instructions:Flammable liquid, soluble or dispersed in water. SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use alcohol foam,water spray or fog.

Special Remarks on Fire Hazards: Vapor may travel considerable distance to source of ignition and flash back.

Special Remarks on Explosion Hazards:Forms explosive mixtures with hydrogen peroxide, acetic acid, nitric acid, nitric acid + sulfuric acid, chromic anydride, chromylchloride, nitrosyl chloride, hexachloromelamine, nitrosyl perchlorate, nitryl perchlorate, permonosulfuric acid, thiodiglycol +hydrogen peroxide, potassium ter-butoxide, sulfur dichloride, 1-methyl-1,3-butadiene, bromoform, carbon, air, chloroform,thitriazylperchlorate.

Section 6: Accidental Release Measures

Small Spill:Dilute with water and mop up, or absorb with an inert dry material and place in an appropriate waste disposal container.

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Large Spill:Flammable liquid. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Absorb with DRY earth,sand or other non-combustible material. Do not touch spilled material. Prevent entry into sewers, basements or confinedareas; dike if needed. Be careful that the product is not present at a concentration level above TLV. Check TLV on the MSDSand with local authorities.

Section 7: Handling and Storage

Precautions:Keep locked up.. Keep away from heat. Keep away from sources of ignition. Ground all equipment containing material. Donot ingest. Do not breathe gas/fumes/ vapor/spray. Wear suitable protective clothing. In case of insufficient ventilation, wearsuitable respiratory equipment. If ingested, seek medical advice immediately and show the container or the label. Avoidcontact with skin and eyes. Keep away from incompatibles such as oxidizing agents, reducing agents, acids, alkalis.

Storage:Store in a segregated and approved area (flammables area) . Keep container in a cool, well-ventilated area. Keep containertightly closed and sealed until ready for use. Keep away from direct sunlight and heat and avoid all possible sources of ignition(spark or flame).

Section 8: Exposure Controls/Personal Protection

Engineering Controls:Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of vapors below their respectivethreshold limit value. Ensure that eyewash stations and safety showers are proximal to the work-station location.

Personal Protection:Splash goggles. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Gloves.

Personal Protection in Case of a Large Spill:Splash goggles. Full suit. Vapor respirator. Boots. Gloves. A self contained breathing apparatus should be used to avoidinhalation of the product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE handling thisproduct.

Exposure Limits:TWA: 500 STEL: 750 (ppm) from ACGIH (TLV) [United States] TWA: 750 STEL: 1000 (ppm) from OSHA (PEL) [UnitedStates] TWA: 500 STEL: 1000 [Austalia] TWA: 1185 STEL: 2375 (mg/m3) [Australia] TWA: 750 STEL: 1500 (ppm) [UnitedKingdom (UK)] TWA: 1810 STEL: 3620 (mg/m3) [United Kingdom (UK)] TWA: 1800 STEL: 2400 from OSHA (PEL) [UnitedStates]Consult local authorities for acceptable exposure limits.

Section 9: Physical and Chemical Properties

Physical state and appearance: Liquid.

Odor: Fruity. Mint-like. Fragrant. Ethereal

Taste: Pungent, Sweetish

Molecular Weight: 58.08 g/mole

Color: Colorless. Clear

pH (1% soln/water): Not available.

Boiling Point: 56.2°C (133.2°F)

Melting Point: -95.35 (-139.6°F)

Critical Temperature: 235°C (455°F)

Specific Gravity: 0.79 (Water = 1)

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Vapor Pressure: 24 kPa (@ 20°C)

Vapor Density: 2 (Air = 1)

Volatility: Not available.

Odor Threshold: 62 ppm

Water/Oil Dist. Coeff.: The product is more soluble in water; log(oil/water) = -0.2

Ionicity (in Water): Not available.

Dispersion Properties: See solubility in water.

Solubility: Easily soluble in cold water, hot water.

Section 10: Stability and Reactivity Data

Stability: The product is stable.

Instability Temperature: Not available.

Conditions of Instability: Excess heat, ignition sources, exposure to moisture, air, or water, incompatible materials.

Incompatibility with various substances: Reactive with oxidizing agents, reducing agents, acids, alkalis.

Corrosivity: Non-corrosive in presence of glass.

Special Remarks on Reactivity: Not available.

Special Remarks on Corrosivity: Not available.

Polymerization: Will not occur.

Section 11: Toxicological Information

Routes of Entry: Absorbed through skin. Dermal contact. Eye contact. Inhalation.

Toxicity to Animals:WARNING: THE LC50 VALUES HEREUNDER ARE ESTIMATED ON THE BASIS OF A 4-HOUR EXPOSURE. Acute oraltoxicity (LD50): 3000 mg/kg [Mouse]. Acute toxicity of the vapor (LC50): 44000 mg/m3 4 hours [Mouse].

Chronic Effects on Humans:CARCINOGENIC EFFECTS: A4 (Not classifiable for human or animal.) by ACGIH. DEVELOPMENTAL TOXICITY: ClassifiedReproductive system/toxin/female, Reproductive system/toxin/male [SUSPECTED]. Causes damage to the following organs:central nervous system (CNS). May cause damage to the following organs: kidneys, the reproductive system, liver, skin.

Other Toxic Effects on Humans:Hazardous in case of skin contact (irritant), of ingestion, of inhalation. Slightly hazardous in case of skin contact (permeator).

Special Remarks on Toxicity to Animals: Not available.

Special Remarks on Chronic Effects on Humans:May affect genetic material (mutagenicity) based on studies with yeast (S. cerevisiae), bacteria, and hamster fibroblast cells.May cause reproductive effects (fertility) based upon animal studies. May contain trace amounts of benzene and formaldehydewhich may cancer and birth defects. Human: passes the placental barrier.

Special Remarks on other Toxic Effects on Humans:Acute Potential Health Effects: Skin: May cause skin irritation. May be harmful if absorbed through the skin. Eyes: Causeseye irritation, characterized by a burning sensation, redness, tearing, inflammation, and possible corneal injury. Inhalation:Inhalation at high concentrations affects the sense organs, brain and causes respiratory tract irritation. It also may affect theCentral Nervous System (behavior) characterized by dizzness, drowsiness, confusion, headache, muscle weakeness, andpossibly motor incoordination, speech abnormalities, narcotic effects and coma. Inhalation may also affect the gastrointestinaltract (nausea, vomiting). Ingestion: May cause irritation of the digestive (gastrointestinal) tract (nausea, vomiting). It may also

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affect the Central Nevous System (behavior), characterized by depression, fatigue, excitement, stupor, coma, headache,altered sleep time, ataxia, tremors as well at the blood, liver, and urinary system (kidney, bladder, ureter) and endocrinesystem. May also have musculoskeletal effects. Chronic Potential Health Effects: Skin: May cause dermatitis. Eyes: Eyeirritation.

Section 12: Ecological Information

Ecotoxicity:Ecotoxicity in water (LC50): 5540 mg/l 96 hours [Trout]. 8300 mg/l 96 hours [Bluegill]. 7500 mg/l 96 hours [Fatthead Minnow].0.1 ppm any hours [Water flea].

BOD5 and COD: Not available.

Products of Biodegradation:Possibly hazardous short term degradation products are not likely. However, long term degradation products may arise.

Toxicity of the Products of Biodegradation: The product itself and its products of degradation are not toxic.

Special Remarks on the Products of Biodegradation: Not available.

Section 13: Disposal Considerations

Waste Disposal:Waste must be disposed of in accordance with federal, state and local environmental control regulations.

Section 14: Transport Information

DOT Classification: CLASS 3: Flammable liquid.

Identification: : Acetone UNNA: 1090 PG: II

Special Provisions for Transport: Not available.

Section 15: Other Regulatory Information

Federal and State Regulations:California prop. 65: This product contains the following ingredients for which the State of California has found to causereproductive harm (male) which would require a warning under the statute: Benzene California prop. 65: This product containsthe following ingredients for which the State of California has found to cause birth defects which would require a warning underthe statute: Benzene California prop. 65: This product contains the following ingredients for which the State of California hasfound to cause cancer which would require a warning under the statute: Benzene, Formaldehyde Connecticut hazardousmaterial survey.: Acetone Illinois toxic substances disclosure to employee act: Acetone Illinois chemical safety act: AcetoneNew York release reporting list: Acetone Rhode Island RTK hazardous substances: Acetone Pennsylvania RTK: AcetoneFlorida: Acetone Minnesota: Acetone Massachusetts RTK: Acetone Massachusetts spill list: Acetone New Jersey: AcetoneNew Jersey spill list: Acetone Louisiana spill reporting: Acetone California List of Hazardous Substances (8 CCR 339):Acetone TSCA 8(b) inventory: Acetone TSCA 4(a) final test rules: Acetone TSCA 8(a) IUR: Acetone

Other Regulations:OSHA: Hazardous by definition of Hazard Communication Standard (29 CFR 1910.1200). EINECS: This product is on theEuropean Inventory of Existing Commercial Chemical Substances.

Other Classifications:

WHMIS (Canada):CLASS B-2: Flammable liquid with a flash point lower than 37.8°C (100°F). CLASS D-2B: Material causing other toxic effects(TOXIC).

p. 6

DSCL (EEC):R11- Highly flammable. R36- Irritating to eyes. S9- Keep container in a well-ventilated place. S16- Keep away from sources ofignition - No smoking. S26- In case of contact with eyes, rinse immediately with plenty of water and seek medical advice.

HMIS (U.S.A.):

Health Hazard: 2

Fire Hazard: 3

Reactivity: 0

Personal Protection: h

National Fire Protection Association (U.S.A.):

Health: 1

Flammability: 3

Reactivity: 0

Specific hazard:

Protective Equipment:Gloves. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Wear appropriate respiratorwhen ventilation is inadequate. Splash goggles.

Section 16: Other Information

References:-Material safety data sheet issued by: la Commission de la Santé et de la Sécurité du Travail du Québec. -The Sigma-Aldrich Library of Chemical Safety Data, Edition II. -Hawley, G.G.. The Condensed Chemical Dictionary, 11e ed., New YorkN.Y., Van Nostrand Reinold, 1987. LOLI, RTECS, HSDB databases. Other MSDSs

Other Special Considerations: Not available.

Created: 10/10/2005 08:13 PM

Last Updated: 11/06/2008 12:00 PM

The information above is believed to be accurate and represents the best information currently available to us. However, wemake no warranty of merchantability or any other warranty, express or implied, with respect to such information, and we assumeno liability resulting from its use. Users should make their own investigations to determine the suitability of the information fortheir particular purposes. In no event shall ScienceLab.com be liable for any claims, losses, or damages of any third party or forlost profits or any special, indirect, incidental, consequential or exemplary damages, howsoever arising, even if ScienceLab.comhas been advised of the possibility of such damages.

MSDS-BP PAGE 1 Issued 12/08/93 Revised 12/12/05

Material Safety Data Sheet(MSDS-BP)

PRODUCT IDENTIFICATION Product Name BLACK POWDER Trade Names and Synonyms N/A Manufacturer/Distributor GOEX, Inc. (Doyline, LA) & various international sources Transportation Emergency 800-255-3924 (24 hrs — CHEM • TEL)

PREVENTION OF ACCIDENTS IN THE USE OF EXPLOSIVES

The prevention of accidents in the use of explosives is a result of careful planning and observance of the best known practices. The explosives user must remember that he is dealing with a powerful force and that various devices and methods have been developed to assist him in directing this force. He should realize that this force, if misdirected, may either kill or injure both him and his fellow workers.

WARNING All explosives are dangerous and must be carefully handled and used following approved safety procedures either by or under the direction of competent, experienced persons in accordance with all applicable federal, state, and local laws, regulations, or ordinances. If you have any questions or doubts as to how to use any explosive product, DO NOT USE IT before consulting with your supervisor, or the manufacturer, if you do not have a supervisor. If your supervisor has any questions or doubts, he should consult the manufacturer before use.

MSDS-BP PAGE 1 Issued 12/08/93 Revised 12/12/05

HAZARDOUS COMPONENTS Material or Component % CAS No. TLV PEL

Potassium nitrate1 70-76 007757-79-1 NE NE

Sodium nitrate1 70-74 007631-99-4 NE NE Charcoal 8-18 N/A NE NE Sulfur 9-20 007704-34-9 NE NE

Graphite2 Trace 007782-42-5 15 mppct (TWA) 2.5 mg/m3

N/A = Not assigned NE = Not established 1 Black Powder contains either potassium nitrate or sodium nitrate in the percentages indicated. Black powder does not contain

both. 2 Not contained in all grades of black powder.

PHYSICAL DATA Boiling Point N/A Vapor Pressure N/A Vapor Density N/A Solubility in Water Good Specific Gravity 1.70 - 1.82 (mercury method) 1.92 - 2.08 (pycnometer) PH 6.0 - 8.0 Evaporation Rate N/A Appearance and Odor Black granular powder. No odor detectable.

HAZARDOUS REACTIVITY Instability Keep away from heat, sparks, and open flame. Avoid impact, friction, and static

electricity. Incompatibility When dry, black powder is compatible with most metals; however, it is hygroscopic, and

when wet, attracts all common metals except stainless steel.

Black powder must be tested for compatibility with any material not specified in the production/procurement package with which they may come in contact. Materials include other explosives, solvents, adhesives, metals, plastics, paints, cleaning compounds, floor and table coverings, packing materials, and other similar materials, situations, and equipment.

Hazardous decomposition Detonation produces hazardous overpressures and fragments (if confined). Gases produced may be toxic if exposed in areas with inadequate ventilation.

Polymerization Polymerization will not occur.

FIRE AND EXPLOSION DATA Flashpoint Not applicable Auto ignition temperature Approx. 464°C (867°F) Explosive temperature (5 sec) Ignites @ approx. 427°C (801°F) Extinguishing media Water Special fire fighting procedures ALL EXPLOSIVES: DO NOT FIGHT EXPLOSIVES FIRES. Try to keep

fire from reaching explosives. Isolate area. Guard against intruders.

Division 1.1 Explosives (heavily encased): Evacuate the area for 5000 feet (1 mile) if explosives are heavily encased.

Division 1.1 Explosives (not heavily encased): Evacuate the area for 2500 feet (½ mile) if explosives are not heavily encased.

Division 1.1 Explosives (all): Consult the 2000 Emergency Response Guidebook, Guide 112 for further details.

Unusual fire and explosion hazards Black powder is a deflagrating explosive. It is very sensitive to flame and spark and can also be ignited by friction and impact. When ignited unconfined, it burns with explosive violence and will explode if ignited under even slight confinement.

MSDS-BP PAGE 2-3 Issued 12/08/93 Revised 12/03/03

HEALTH HAZARDS

General Black powder is a Division 1.1 Explosive, and detonation may cause severe physical injury, including death. All explosives are dangerous and must be handled carefully and used following approved safety procedures under the direction of competent, experienced persons in accordance with all applicable federal, state, and local laws, regulations, and ordinances.

Carcinogenicity None of the components of Black powder are listed as a carcinogen by NTP, IARC, or OSHA.

FIRST AID Inhalation Not a likely route of exposure. If inhaled, remove to fresh air. If not breathing, give

artificial respiration, preferably by mouth-to-mouth. If breathing is difficult, give oxygen. Seek prompt medical attention.

Eye and skin contact Not a likely route of exposure. Flush eyes with water. Wash skin with soap and water. Ingestion Not a likely route of exposure.. If ingested, induce vomiting immediately by giving two

glasses of water and sticking finger down throat. Injury from detonation Seek prompt medical attention.

SPILL OR LEAK PROCEDURES Spill/leak response Use appropriate personal protective equipment. Isolate area and remove sources of

friction, impact, heat, low level electrical current, electrostatic or RF energy. Only competent, experienced persons should be involved in cleanup procedures.

Carefully pick up spills with non-sparking and non-static producing tools. Waste disposal Desensitize by diluting in water. Open train burning, by qualified personnel, may be used

for disposal of small unconfined quantities. Dispose of in compliance with federal regulations under the authority of the Resource Conservation and Recovery Act (40 CFR Parts 260-271).

SPECIAL PROTECTION INFORMATION Ventilation Use only with adequate ventilation. Respiratory None Eye None Gloves Impervious rubber gloves. Other Metal-free and non-static producing clothes

SPECIAL PRECAUTIONS Keep away from friction, impact, and heat. Do not consume food, drink, or tobacco in areas where they may become contaminated with these materials.

Contaminated equipment must be thoroughly water cleaned before attempting repairs.

Use only non-spark producing tools.

No smoking.

MSDS-BP PAGE 2-4 Issued 12/08/93 Revised 12/03/03

STORAGE CONDITIONS Store in a cool, dry place in accordance with the requirements of Subpart K, ATF: Explosives Law and Regulations (27 CFR 55.201-55.219).

SHIPPING INFORMATION Proper shipping name Black powder Hazard class 1.1D UN Number UN0027 DOT Label & Placard DOT Label EXPLOSIVE 1.1D DOT Placard EXPLOSIVES 1.1 Alternate shipping information Limited quantities of black powder may be transported as “Black powder for small arms”,

NA0027, class 4.1 pursuant to U.S. Department of Transportation authorization EX-8712212.

The information contained in this Material Safety Data Sheet is based upon available data and believed to be correct; however, as such has been obtained from various sources, including the manufacturer and independent laboratories, it is given without warranty or representation that it is complete, accurate, and can be relied upon. OWEN COMPLIANCE SERVICES, INC. has not attempted to conceal in any manner the deleterious aspects of the product listed herein, but makes no warranty as to such. Further, OWEN COMPLIANCE SERVICES, INC. cannot anticipate nor control the many situations in which the product or this information may be used; there is no guarantee that the health and safety precautions suggested will be proper under all conditions. It is the sole responsibility of each user of the product to determine and comply with the requirements of all applicable laws and regulations regarding its use. This information is given solely for the purposes of safety to persons and property. Any other use of this information is expressly prohibited.

For further information contact: David W. Boston, President OWEN COMPLIANCE SERVICES, INC. 12001 County Road 1000 P.O. Box 765 Godley, TX 76044

Telephone number: 817-551-0660 FAX number: 817-396-4584

MSDS prepared by: David W. Boston Original publication date: 12/08/93 Revision date: 12/12/05

12/03/03

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 1 of 11 MSDS No.:15-MSD-21555

Section 1: Product and Company Information

Product Name(s): Woven Unidirectional Fiberglass Fabric (A-Style WarpUnidirectional), Stitchbonded Fiberglass Fabric, Woven Fiberglass Fabric

Manufacturer: Owens-Corning, World Headquarters, One Owens-Corning ParkwayAttn. Product Stewardship, Toledo, OH, 43659,Telephone: 1-419-248-8234 (8am-5pm ET weekdays).OC Fabrics, 1851 S. Sequin Ave., New Braunfels, TX, 78130Telephone: 1-210-629-4009 (8am-5pm CT weekdays).

Emergency Contacts:Emergencies ONLY (after 5pm ET and weekends): 1-419-248-5330,CHEMTREC (24 hours everyday): 1-800-424-9300,CANUTEC (Canada- 24 hours everyday): 1-613-996-6666.

Health and Technical Contacts:Health Issues Information (8am-5pm ET):1-419-248-8234,Technical Product Information (8am-5pm ET): 1-800-GET-PINK.

Section 2: Composition and Ingredient Information

Common Name Chemical Name CAS No. Wt. %Non-Hazardous Ingredients

Fiber Glass ContinuousFilament (non respirable)

Fibrous Glass 65997-17-3 94-100

Size Size None 0-2

Polyester Yarn Polyester Yarn None 0-4

Note: See Section 8 of MSDS for exposure limit data for these ingredients.

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 2 of 11 MSDS No.:15-MSD-21555

Section 3: Hazards Identification

Appearance and Odor: White/off-white colored solid with no odor.

Emergency Overview

No unusual conditions are expected from this product

Primary Route(s) of Exposure: inhalation, skin, eye

Potential Health Effects:

ACUTE (short term): Fiber glass continuous filament is a mechanical irritant.Breathing dusts and fibers may cause short term irritation of the mouth, noseand throat. Skin contact with dust and fibers may cause itching and short termirritation. Eye contact with dust and fibers may cause short term mechanicalirritation. Ingestion may cause short term mechanical irritation of the stomachand intestines. See Section 8 for exposure controls.

CHRONIC (long term): There is no known health effects connected with longterm use or contact with this product. See Section 11 of MSDS for moretoxicological data.

Medical Conditions Aggravated by Exposure: Long term breathing or skinconditions that are aggravated by mechanical irritants may be at a higher risk forworsening from use or contact with this product.

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 3 of 11 MSDS No.:15-MSD-21555

Section 4: First Aid Measures

Inhalation: Move person to fresh air. Seek medical attention if irritation persists.

Eye Contact: Flush eyes with running water for at least 15 minutes. Seek medicalattention if irritation persists.

Skin Contact: Wash with mild soap and running water. Use a washcloth to helpremove fibers. To avoid more irritation, do not rub or scratch affected areas.Rubbing or scratching may force fibers into skin. Seek medical attention ifirritation persists.

Ingestion: Ingestion of this material is unlikely. If it does occur, watch the person forseveral days to make sure that intestinal blockage does not occur.

Section 5: Fire Fighting Measures

Flash Point and Method: None

Flammability Limits (%): None.

Auto Ignition Temperature: Not Applicable.

Extinguishing Media: Water, foam, CO2 or dry chemical.

Unusual Fire and Explosion Hazards: None known.

Fire Fighting Instructions: Use self contained breathing apparatus (SCBA) in asustained fire.

Hazardous Combustion Products: Primary combustion products are carbonmonoxide, carbon dioxide and water. Other undetermined compounds could bereleased in small quantities.

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 4 of 11 MSDS No.:15-MSD-21555

Section 6: Accidental Release Measures

Land Spill: Scoop up material and put into suitable container for disposal as a non-hazardous waste.

Water Spill: This material will sink and disperse along the bottom of waterways andponds. It can not easily be removed after it is waterborne; however, the materialis non-hazardous in water.

Air Release: This material will settle out of the air. If concentrated on land it can thenbe scooped up for disposal as a non-hazardous waste.

Section 7: Handling and Storage

Storage Temperature: Not applicable.

Storage Pressure: Not applicable.

General: No special storage or handling procedures are required for this material.

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 5 of 11 MSDS No.:15-MSD-21555

Section 8: Exposure Controls and Personal Protection

Ingredient OSHA PEL(8-hr TWA)

ACGIH TLV(8-hr TWA)

Fiber Glass Continuous Filament 5 mg/m3(respirable dust)

15 mg/m3(total dust1 fiber/cc

(proposed)

10 mg/m3(inhalable)3 mg/m3

(respirable)

Size None Established None Established

Polyester Yarn 5 mg/m3(respirable dust)

15 mg/m3(total dust

10 mg/m3(inhalable)3 mg/m3

(respirable)

Ventilation: General dilution ventilation and/or local exhaust ventilation should beprovided as necessary to maintain exposures below regulatory limits.

Personal Protection:

Respiratory Protection: A properly fitted NIOSH/MSHA approved disposabledust respirator such as the 3M model 8210 (or 8710) or model 9900 (inhigh humidity environments) or equivalent should be used when: highdust levels are encountered; the level of glass fibers in the air exceedsthe OSHA permissible limits; or if irritation occurs. Use respiratoryprotection in accordance with your company's respiratory protectionprogram, local regulations and OSHA regulations under 29 CFR1910.134.

Skin Protection: Loose fitting long sleeved shirt that covers to the base of theneck, long pants and gloves. Skin irritation is known to occur chiefly atpressure points such as around neck, wrist, waist and between fingers.

Eye Protection: Safety glasses or goggles.

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 6 of 11 MSDS No.:15-MSD-21555

Work and Hygienic Practices: Handle using good industrial hygiene and safetypractices. Avoid unnecessary contact with dusts and fibers by using good localexhaust ventilation. Remove material from the skin and eyes after contact.Remove material from clothing using vacuum equipment (never use compressedair and always wash work clothes separately from other clothing. Wipe out thewasher or sink to prevent loose glass fibers from getting on other clothing).Keep the work area clean of dusts and fibers made during fabrication by usingvacuum equipment to clean up dusts and fibers (avoid sweeping or usingcompressed air as these techniques re-suspend dusts and fibers into the air.)Have access to safety showers and eye wash stations.

Section 9: Physical and Chemical Properties

Vapor Pressure (mm Hg @ 20oC): Not Applicable pH: Not Applicable

Vapor Density (Air=1): Not Applicable

Specific Gravity (Water=1): 2.60 Boiling Point: Not Applicable

Solubility in Water: Insoluble Viscosity: Not Applicable

Appearance: Solid Physical State: Solid

Odor Type: None Freezing Point: Not Applicable

Evaporation Rate (n-Butyl Acetate=1): Not Applicable

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 7 of 11 MSDS No.:15-MSD-21555

Section 10: Stability and Reactivity

General: Stable

Incompatible Materials and Conditions to Avoid: None

Hazardous Decomposition Products: Sizings or binders may decompose in a fire.See Section 5 of MSDS for combustion products statement.

Hazardous Polymerization: Will not occur.

Section 11: Toxicological Information

CARCINOGENICITY: The table below indicates whether or not each agency has listedeach ingredients as a carcinogen:

Ingredient ACGIH IARC NTP OSHAFiber GlassContinuous Filament

A4 3 No No

Size No No No No

Polyester Yarn No No No No

LD50 Oral(g/kg)

LD50 Dermal(g/kg)

LC50 Inhalation(ppm, 8 hrs.)

Fiber GlassContinuous Filament

Not Available Not Available Not Available

Size Not Available Not Available Not Available

Polyester Yarn Not Available Not Available Not Available

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 8 of 11 MSDS No.:15-MSD-21555

Fiber Glass Continuous Filament: The International Agency for Research on Cancer(IARC) in June, 1987, categorized fiber glass continuous filament as notclassifiable with respect to human carcinogenicity (Group 3). The evidence fromhuman as well as animal studies was evaluated by IARC as insufficient toclassify fiber glass continuous filament as a possible, probable, or confirmedcancer causing material.

Section 12: Ecological Information

This material is not expected to cause harm to animals, plants or fish.

Section 13: Disposal Considerations

RCRA Hazard Class: Non-hazardous.

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 9 of 11 MSDS No.:15-MSD-21555

Section 14: Transport Information

DOT Shipping Names: Not regulated

Hazard Class or Division: None Secondary: None

Identification No.: None Packing Group: None

Label(s) required (if not excepted): None

Special Provisions: None Packaging Exceptions: None

Non-bulk Packaging: None Bulk packaging: None

EPA Hazardous Substances: None RQ: None

Quantity Limitations: Passenger Aircraft: NoneCargo Aircraft: None

Marine Pollutants: None

Freight Description: None

Hazardous Material Shipping Description: None

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 10 of 11 MSDS No.:15-MSD-21555

Transportation of Dangerous Goods - Canada

Proper Shipping Name: Not Regulated

TDG Hazard Classification: (Primary): None (Secondary): None

IMO Classification: None

ICAO/IATA Classification: None

Product Identification Number: None

Packing Group: None

Control Temperature: None Emergency Temperature: None

Schedule XII Quantity Restriction: None

Reportable Quantity for US Shipments: None

IATA Packing Instructions: Passenger/Cargo: NoneCargo Only: NoneLimited Quantity: None

Maximum Net Quantity per Package: Passenger/Cargo: NoneCargo Only: NoneLimited Quantity: None

Special Provisions: None

™ MATERIAL SAFETY DATA SHEET

Prepared: 25 February, 1997 Page: 11 of 11 MSDS No.:15-MSD-21555

Section 15: Regulatory Information

TSCA Status: Each ingredient is on the Inventory.

NSR Status (Canada): Each ingredient is on the DSL.

SARA Title III: Hazard Categories:Acute Health: YesChronic Health: NoFire Hazard: NoPressure Hazard: NoReactivity Hazard: No

Reportable Ingredients:Sec. 302/304: NoneSec. 313: None

California Proposition 65: No ingredient is listed.

Clean Air Act: No ingredient is listed.

WHMIS (Canada): Status: Not ControlledWHMIS Classification(s): None

Section 16: Other Information

HMIS and NFPA Hazard Rating: Category HMIS NFPAAcute Health 1 1Flammability 0 0Reactivity 0 0

NFPA Unusual Hazards: None.HMIS Personal Protection: To be supplied by user depending upon use.

Revision Summary: This is a new MSDS. (Reformatted 11/25/98)

®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow*R means resistance to heat flow. The higher the R-value or RSI, the greater the insulating power.

STYROFOAM™ Highload 40, 60 and100 Extruded Polystyrene Insulation

C O M M E R C I A L

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ManufacturerThe Dow Chemical CompanyBuilding Solutions200 LarkinMidland, MI 486741-866-583-BLUE (2583)Fax 1-989-832-1465www.dowstyrofoam.com/architect

Dow Chemical Canada Inc.Building Solutions 250 – 6th Ave. SW, Suite 2200Calgary, AB T2P 3H71-866-583-BLUE (2583) (English)1-800-363-6210 (French)www.dowstyrofoam.ca/4architects

ProductDescription

STYROFOAM™ Highload extrudedpolystyrene insulation is aclosed-cell foam insulation.Available in compressivestrengths of 40, 60 and 100 psi(275, 415 and 690 kPa),

1

2

3

P R O D U C T N A M E

STYROFOAM Highload insulationfeatures superior moisture resist-ance and R-value* retention. Allthree STYROFOAM Highloadinsulation products resist compressive creep and fatigue,delivering long-term compressivestrength. Like all STYROFOAMinsulation products, STYROFOAMHighload 40, 60 and 100 aredurable, versatile and reusable –making them the preferredchoices for a variety of high-load applications.

BASIC USESTYROFOAM™ Highload insulationis ideal for use in low-temperature(freezer floor) applications, high-ways, airport runways, bridgeabutments, parking decks, utilitylines, ice rinks and plaza decks. Itis the responsibility of the designerto select the proper STYROFOAMHighload insulation productbased on the dead and live loadsexpected in the application.

SIZESIN THE U.S.:Butt EdgeThickness:

2" or 3" STYROFOAM™

Highload 40 and 602" STYROFOAM™ Highload 100

Width and length:2' x 8' STYROFOAM

Highload 40, 60 and 1004' x 8' STYROFOAM

Highload 40

IN CANADA:Butt EdgeThickness:

1", 1.5", 2" or 3" (25 mm, 38 mm, 50 mm or 75 mm) STYROFOAM Highload 40 and 60

2" or 3" (50 mm or 75 mm)STYROFOAM Highload 100

Width and length:2' x 8' (600 mm x 2,400 mm)

STYROFOAM Highload 40, 60 and 100

P R O D U C T I N F O R M A T I O NUnited States/

Canada C O M M E R C I A L

Property and Test Method ValueHighload 40 Highload 60 Highload 100

Thermal Resistance(1), per inch, ASTM C518, C177, @ 75°F mean temp., ft2•h•°F/Btu, R-value, min. 5.0 5.0 5.0

Compressive Strength(2), ASTM D1621, psi, min. 40 60 100 Water Absorption, ASTM C272, % by volume, max. (24hr water immersion) 0.1 0.1 0.1Water Vapor Permeance(3), ASTM E96, perms 0.8 0.8 0.8 Maximum Use Temperature, °F 165 165 165 Coefficient of Linear Thermal Expansion, ASTM D696, in/in•°F 3.5 x 10-5 3.5 x 10-5 3.5 x 10-5

Flexural Strength, ASTM C203, psi, min. 60 75 100 Complies with ASTM C578, Type VI VII V

Physical Properties of STYROFOAM™ Highload 40, 60 and 100 InsulationTA B L E 1

(1) For 1" material(2) Vertical compressive strength is measured at 5 percent deformation or at yield, whichever occurs first. Since STYROFOAM insulations are visco-elastic materials, adequate design safety factors

should be used to prevent long-term creep. For static loads, 3:1 is suggested. For dynamic loads, call 1-866-583-BLUE (2583) for safety factor recommendation.(3) Water vapor permeance varies with product type and thickness. Values are based on the desiccant method and they apply to insulation 1" or greater in thickness.

U . S . P R O P E R T Y C H A R T

P R O D U C T I N F O R M A T I O N

Technical DataAPPLICABLE STANDARDS STYROFOAM™ Highload 40, 60and 100 insulation meets ASTMC578 – Standard Specificationfor Rigid Cellular PolystyreneThermal Insulation. ApplicableASTM standards include:• C518 – Standard Test Method

for Steady-State ThermalTransmission Properties byMeans of the Heat Flow MeterApparatus

• C177 – Standard Test Methodfor Steady-State Heat FluxMeasurements and ThermalTransmission Properties byMeans of the Guarded-Hot-Plate Apparatus

• D1621 – Standard TestMethod for CompressiveProperties of Rigid CellularPlastics

• D2842 – Standard TestMethod for Water Absorptionof Rigid Cellular Plastics

• E96 – Standard Test Methodsfor Water Vapor Transmissionof Materials

• C272 - Standard Test Methodfor Water Absorption of CoreMaterials for StructuralSandwich Constructions

• D696 – Standard Test Methodfor Coefficient of LinearThermal Expansion of PlasticsBetween -30˚C and 30˚C Witha Vitreous Silica Dilatometer

2

®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

4Acid, inorganic, weak ExcellentAcid, inorganic, strong ExcellentAcid, organic, weak ExcellentAcid, organic, strong GoodBases ExcellentAlcohols, including isopropyl alcohol ExcellentMethyl ethyl ketone Not recommendedPolyglycols, including propylene glycol ExcellentHydrocarbons Not recommendedSalts ExcellentInsecticides Not recommendedKerosene PoorMineral oil USP ExcellentNaphtha (VMP) Not recommendedTurpentine Not recommendedBeer GoodGasoline Not recommendedFruit juices Good

Chemical Resistance(1) of STYROFOAM™ Highload 40, 60 and 100 Insulation TA B L E 3

(1) Explanation of ratings: Excellent = The plastic was unaffected for the duration of the test. Good = A very slight clouding or discoloration of the plastic.Poor = Considerable change in plastic during exposure.Not recommended = Severe attack of the plastic. Became softand unusable after a few hours of exposure.

NOTE: This table should be used as a guide only. For designpurposes, specific test data on the intended application maybe needed.

Property and Test Method ValueHighload 40 Highload 60 Highload 100

Thermal Resistance(1), per inch (25 mm), ASTM C518, C177, @ 75°F (24°C) mean temp., ft2•h•°F/Btu (m2•°C/W), R-value (RSI), min. 5.0 (.88) 5.0 (.88) 5.0 (.88)

Compressive Strength(2), ASTM D1621, psi (kPa), min. 40 (275) 60 (415) 100 (690)Water Absorption, ASTM D2842, % by volume, max. (96hr water immersion) 0.7 0.7 0.7Water Vapour Permeance(3), ASTM E96, perms (ng/Pa•s•m2) 0.6 (35) 0.6 (35) 0.6 (35)Maximum Use Temperature, °F (°C) 165 (74) 165 (74) 165 (74)Coefficient of Linear Thermal Expansion, ASTM D696, in/in•°F (mm/m•°C) 3.5 x 10-5 3.5 x 10-5 3.5 x 10-5

(6.3 x 10-2) (6.3 x 10-2) (6.3 x 10-2)Flexural Strength, ASTM C203, psi (kPa), min. 70 (480) 85 (585) 85 (585)Compressive Modulus (typical), ASTM D1621, psi (kPa) 1,400 (9,650) 2,200 (15,170) 3,700 (25,510)Complies with CAN/ULC S701, Type 4 4 4

TA B L E 2

(1) For 1" (25 mm) material(2) Vertical compressive strength is measured at 5 percent deformation or at yield, whichever occurs first. Since STYROFOAM insulations are visco-elastic materials, adequate design safety factors

should be used to prevent long-term creep. For static loads, 3:1 is suggested. For dynamic loads, call 1-866-583-BLUE (2583) for safety factor recommendation.(3) Water vapour permeance varies with product type and thickness. Values are based on the desiccant method and they apply to insulation 1" (25 mm) or greater in thickness.

• C203 – Standard Test Methodsfor Breaking Load andFlexural Properties of Block-Type Thermal Insulation

CODE COMPLIANCESTYROFOAM™ Highload 40, 60and 100 insulation complieswith the following codes:• International Residential

Code (IRC) and InternationalBuilding Code (IBC); see ICC-ES NER-699,BOCA-ES RR 21-02

• ICBO-ES ER-2275• Calif. Std. Reg. #CA T064• Underwriters Laboratories,

Inc. (UL) Classified, seeClassification Certificate D369

Contact your Dow sales repre-sentative or local authorities for state/provincial and localbuilding code requirements andrelated acceptances.

C A N A D A P R O P E R T Y C H A R T

Physical Properties of STYROFOAM™ Highload 40, 60 and 100 Insulation

WarrantyIn the United States, a 15-yearlimited thermal warranty isavailable.

MaintenanceNot applicable.

TechnicalServices

Dow can provide technical infor-mation to help address questionswhen using STYROFOAM™ 40, 60 and 100 insulation products.Technical personnel are available toassist with any insulation project.For technical assistance call:1-866-583-BLUE (2583) (English)1-800-363-6210 (French)

Filing Systems• www.dowstyrofoam.com/architect• www.dowstyrofoam.ca/4architects• www.sweets.com

PHYSICAL/CHEMICALPROPERTIESSTYROFOAM™ Highload 40, 60and 100 insulation productsexhibit the physical propertiesindicated in Tables 1 and 2when tested as represented.

For chemical resistance prop-erties of STYROFOAM Highload40, 60 and 100 insulation products, see Table 3.

ENVIRONMENTAL DATASTYROFOAM™ Highload 40, 60and 100 insulation is manufac-tured with HCFC blowing agentswhich have 94 percent lessozone depletion potential thanstandard CFC blowing agents.

STYROFOAM extruded polystyrene insulation productsare reusable in many applications.

FIRE PROTECTIONSTYROFOAM™ Highload 40, 60 and 100 insulation is combustible; protect from highheat sources. Local buildingcodes may require a protectiveor thermal barrier. For moreinformation, consult MSDS, callDow at 1-866-583-BLUE (2583)or contact your local buildinginspector.

Installation STYROFOAM™ Highload 40, 60and 100 insulation boards areeasy to handle and install. Theycan be cut with a utility knifeor any sharp blade. Contact alocal Dow representative oraccess the literature library atwww.dowstyrofoam.com/architector www.dowstyrofoam.ca/4architectsfor more specific instructions.

AvailabilitySTYROFOAM™ Highload 40, 60and 100 insulation productsare distributed through anextensive network. For moreinformation, call: 1-800-232-2436 (English)1-800-565-1255 (French)

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®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

NOTICE: No freedom from any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, Customeris responsible for determining whether products and the information in this document are appropriate for Customer’s use and for ensuring that Customer’s workplace and disposal practices are in compliancewith applicable laws and other government enactments. Dow assumes no obligation or liability for the information in this document. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.

COMBUSTIBLE: Protect from high heat sources. Local building codes may require a protective or thermal barrier. For more information, consult MSDS, call Dow at 1-866-583-BLUE (2583) or contact yourlocal building inspector. In an emergency, call 1-989-636-4400 in the U.S. or 1-519-339-3711 in Canada.

Building and/or construction practices unrelated to building materials could greatly affect moisture and the potential for mold formation. No material supplier including Dow can give assurance that moldwill not develop in any specific system.

IN THE U.S.:• For Technical Information: 1-866-583-BLUE (2583)• For Sales Information: 1-800-232-2436

THE DOW CHEMICAL COMPANY• Building Solutions • 200 Larkin • Midland, MI 48674www.dowstyrofoam.com/architect

IN CANADA:• For Technical Information: 1-866-583-BLUE (2583) (English); 1-800-363-6210 (French) • For Sales Information: 1-800-232-2436 (English); 1-800-565-1255 (French)

DOW CHEMICAL CANADA INC.• Building Solutions • Suite 2200 • 250 – 6th Ave. SW • Calgary, AB T2P 3H7www.dowstyrofoam.ca/4architects

Form No. 179-02548X-0807DM178-00202X-0807DM

McKay189699

Printed in U.S.A. ®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Habitat for Humanity is a registered service mark owned by Habitat for Humanity International

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Material Safety Data SheetLead MSDS

Section 1: Chemical Product and Company Identification

Product Name: Lead

Catalog Codes: SLL1291, SLL1669, SLL1081, SLL1459,SLL1834

CAS#: 7439-92-1

RTECS: OF7525000

TSCA: TSCA 8(b) inventory: Lead

CI#: Not available.

Synonym: Lead Metal, granular; Lead Metal, foil; LeadMetal, sheet; Lead Metal, shot

Chemical Name: Lead

Chemical Formula: Pb

Contact Information:Sciencelab.com, Inc.14025 Smith Rd.Houston, Texas 77396US Sales: 1-800-901-7247International Sales: 1-281-441-4400Order Online: ScienceLab.com

CHEMTREC (24HR Emergency Telephone), call:1-800-424-9300

International CHEMTREC, call: 1-703-527-3887

For non-emergency assistance, call: 1-281-441-4400

Section 2: Composition and Information on IngredientsComposition:

Name CAS # % by Weight

Lead 7439-92-1 100

Toxicological Data on Ingredients: Lead LD50: Not available. LC50: Not available.

Section 3: Hazards Identification

Potential Acute Health Effects: Slightly hazardous in case of skin contact (irritant), of eye contact (irritant), of ingestion, ofinhalation.

Potential Chronic Health Effects:Slightly hazardous in case of skin contact (permeator). CARCINOGENIC EFFECTS: Classified A3 (Proven for animal.) byACGIH, 2B (Possible for human.) by IARC. MUTAGENIC EFFECTS: Not available. TERATOGENIC EFFECTS: Not available.DEVELOPMENTAL TOXICITY: Not available. The substance may be toxic to blood, kidneys, central nervous system (CNS).Repeated or prolonged exposure to the substance can produce target organs damage.

Section 4: First Aid Measures

Eye Contact:

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Check for and remove any contact lenses. In case of contact, immediately flush eyes with plenty of water for at least 15minutes. Get medical attention if irritation occurs.

Skin Contact: Wash with soap and water. Cover the irritated skin with an emollient. Get medical attention if irritation develops.

Serious Skin Contact: Not available.

Inhalation:If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medicalattention.

Serious Inhalation: Not available.

Ingestion:Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconsciousperson. If large quantities of this material are swallowed, call a physician immediately. Loosen tight clothing such as a collar,tie, belt or waistband.

Serious Ingestion: Not available.

Section 5: Fire and Explosion Data

Flammability of the Product: May be combustible at high temperature.

Auto-Ignition Temperature: Not available.

Flash Points: Not available.

Flammable Limits: Not available.

Products of Combustion: Some metallic oxides.

Fire Hazards in Presence of Various Substances: Non-flammable in presence of open flames and sparks, of shocks, ofheat.

Explosion Hazards in Presence of Various Substances:Risks of explosion of the product in presence of mechanical impact: Not available. Risks of explosion of the product inpresence of static discharge: Not available.

Fire Fighting Media and Instructions:SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use water spray, fog or foam. Do not use water jet.

Special Remarks on Fire Hazards: When heated to decomposition it emits highly toxic fumes of lead.

Special Remarks on Explosion Hazards: Not available.

Section 6: Accidental Release Measures

Small Spill:Use appropriate tools to put the spilled solid in a convenient waste disposal container. Finish cleaning by spreading water onthe contaminated surface and dispose of according to local and regional authority requirements.

Large Spill:Use a shovel to put the material into a convenient waste disposal container. Finish cleaning by spreading water on thecontaminated surface and allow to evacuate through the sanitary system. Be careful that the product is not present at aconcentration level above TLV. Check TLV on the MSDS and with local authorities.

Section 7: Handling and Storage

Precautions:Keep locked up.. Keep away from heat. Keep away from sources of ignition. Empty containers pose a fire risk, evaporatethe residue under a fume hood. Ground all equipment containing material. Do not ingest. Do not breathe dust. Wear suitable

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protective clothing. If ingested, seek medical advice immediately and show the container or the label. Keep away fromincompatibles such as oxidizing agents.

Storage: Keep container tightly closed. Keep container in a cool, well-ventilated area.

Section 8: Exposure Controls/Personal Protection

Engineering Controls:Use process enclosures, local exhaust ventilation, or other engineering controls to keep airborne levels below recommendedexposure limits. If user operations generate dust, fume or mist, use ventilation to keep exposure to airborne contaminantsbelow the exposure limit.

Personal Protection: Safety glasses. Lab coat. Dust respirator. Be sure to use an approved/certified respirator or equivalent.Gloves.

Personal Protection in Case of a Large Spill:Splash goggles. Full suit. Dust respirator. Boots. Gloves. A self contained breathing apparatus should be used to avoidinhalation of the product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE handling thisproduct.

Exposure Limits:TWA: 0.05 (mg/m3) from ACGIH (TLV) [United States] TWA: 0.05 (mg/m3) from OSHA (PEL) [United States] TWA: 0.03 (mg/m3) from NIOSH [United States] TWA: 0.05 (mg/m3) [Canada]Consult local authorities for acceptable exposure limits.

Section 9: Physical and Chemical Properties

Physical state and appearance: Solid. (Metal solid.)

Odor: Not available.

Taste: Not available.

Molecular Weight: 207.21 g/mole

Color: Bluish-white. Silvery. Gray

pH (1% soln/water): Not applicable.

Boiling Point: 1740°C (3164°F)

Melting Point: 327.43°C (621.4°F)

Critical Temperature: Not available.

Specific Gravity: 11.3 (Water = 1)

Vapor Pressure: Not applicable.

Vapor Density: Not available.

Volatility: Not available.

Odor Threshold: Not available.

Water/Oil Dist. Coeff.: Not available.

Ionicity (in Water): Not available.

Dispersion Properties: Not available.

Solubility: Insoluble in cold water.

Section 10: Stability and Reactivity Data

p. 4

Stability: The product is stable.

Instability Temperature: Not available.

Conditions of Instability: Incompatible materials, excess heat

Incompatibility with various substances: Reactive with oxidizing agents.

Corrosivity: Non-corrosive in presence of glass.

Special Remarks on Reactivity:Can react vigorously with oxidizing materials. Incompatible with sodium carbide, chlorine trifluoride, trioxane + hydrogenperoxide, ammonium nitrate, sodium azide, disodium acetylide, sodium acetylide, hot concentrated nitric acid, hotconcentrated hydrochloric acid, hot concentrated sulfuric acid, zirconium.

Special Remarks on Corrosivity: Not available.

Polymerization: Will not occur.

Section 11: Toxicological Information

Routes of Entry: Absorbed through skin. Inhalation. Ingestion.

Toxicity to Animals:LD50: Not available. LC50: Not available.

Chronic Effects on Humans:CARCINOGENIC EFFECTS: Classified A3 (Proven for animal.) by ACGIH, 2B (Possible for human.) by IARC. May causedamage to the following organs: blood, kidneys, central nervous system (CNS).

Other Toxic Effects on Humans: Slightly hazardous in case of skin contact (irritant), of ingestion, of inhalation.

Special Remarks on Toxicity to Animals: Not available.

Special Remarks on Chronic Effects on Humans: Not available.

Special Remarks on other Toxic Effects on Humans:Acute Potential: Skin: Lead metal granules or dust: May cause skin irritation by mechanical action. Lead metal foil, shot orsheets: Not likely to cause skin irritation Eyes: Lead metal granules or dust: Can irritate eyes by mechanical action. Leadmetal foil, shot or sheets: No hazard. Will not cause eye irritation. Inhalation: In an industrial setting, exposure to lead mainlyoccurs from inhalation of dust or fumes. Lead dust or fumes: Can irritate the upper respiratory tract (nose, throat) as well asthe bronchi and lungsby mechanical action. Lead dust can be absorbed through the respiratory system. However, inhaledlead does not accumulate in the lungs. All of an inhaled dose is eventually abssorbed or transferred to the gastrointestinaltract. Inhalation effects of exposure to fumes or dust of inorganic lead may not develop quickly. Symptoms may includemetallic taste, chest pain, decreased physical fitness, fatigue, sleep disturbance, headache, irritability, reduces memory,mood and personality changes, aching bones and muscles, constipation, abdominal pains, decreasing appetite. Inhalationof large amounts may lead to ataxia, deliriuim, convulsions/seizures, coma, and death. Lead metal foil, shot, or sheets:Not an inhalation hazard unless metal is heated. If metal is heated, fumes will be released. Inhalation of these fumes maycause "fume metal fever", which is characterized by flu-like symptoms. Symptoms may include metallic taste, fever, nausea,vomiting, chills, cough, weakness, chest pain, generalized muscle pain/aches, and increased white blood cell count. Ingestion:Lead metal granules or dust: The symptoms of lead poisoning include abdominal pain or cramps (lead cholic), spasms,nausea, vomiting, headache, muscle weakness, hallucinations, distorted perceptions, "lead line" on the gums, metallic taste,loss of appetite, insomnia, dizziness and other symptoms similar to that of inhalation. Acute poisoning may result in highlead levels in the blood and urine, shock, coma and death in extreme cases. Lead metal foil, shot or sheets: Not an ingestionhazard for usual industrial handling.

Section 12: Ecological Information

Ecotoxicity: Not available.

BOD5 and COD: Not available.

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Products of Biodegradation:Possibly hazardous short term degradation products are not likely. However, long term degradation products may arise.

Toxicity of the Products of Biodegradation: The products of degradation are less toxic than the product itself.

Special Remarks on the Products of Biodegradation: Not available.

Section 13: Disposal Considerations

Waste Disposal:Waste must be disposed of in accordance with federal, state and local environmental control regulations.

Section 14: Transport Information

DOT Classification: Not a DOT controlled material (United States).

Identification: Not applicable.

Special Provisions for Transport: Not applicable.

Section 15: Other Regulatory Information

Federal and State Regulations:California prop. 65: This product contains the following ingredients for which the State of California has found to cause cancer,birth defects or other reproductive harm, which would require a warning under the statute: Lead California prop. 65: Thisproduct contains the following ingredients for which the State of California has found to cause reproductive harm (female)which would require a warning under the statute: Lead California prop. 65: This product contains the following ingredients forwhich the State of California has found to cause reproductive harm (male) which would require a warning under the statute:Lead California prop. 65 (no significant risk level): Lead: 0.0005 mg/day (value) California prop. 65: This product contains thefollowing ingredients for which the State of California has found to cause birth defects which would require a warning underthe statute: Lead California prop. 65: This product contains the following ingredients for which the State of California has foundto cause cancer which would require a warning under the statute: Lead Connecticut hazardous material survey.: Lead Illinoistoxic substances disclosure to employee act: Lead Illinois chemical safety act: Lead New York release reporting list: LeadRhode Island RTK hazardous substances: Lead Pennsylvania RTK: Lead

Other Regulations:OSHA: Hazardous by definition of Hazard Communication Standard (29 CFR 1910.1200). EINECS: This product is on theEuropean Inventory of Existing Commercial Chemical Substances.

Other Classifications:

WHMIS (Canada): CLASS D-2A: Material causing other toxic effects (VERY TOXIC).

DSCL (EEC):R20/22- Harmful by inhalation and if swallowed. R33- Danger of cumulative effects. R61- May cause harm to the unborn child.R62- Possible risk of impaired fertility. S36/37- Wear suitable protective clothing and gloves. S44- If you feel unwell, seekmedical advice (show the label when possible). S53- Avoid exposure - obtain special instructions before use.

HMIS (U.S.A.):

Health Hazard: 1

Fire Hazard: 0

Reactivity: 0

Personal Protection: E

National Fire Protection Association (U.S.A.):

Health: 1

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Flammability: 0

Reactivity: 0

Specific hazard:

Protective Equipment:Gloves. Lab coat. Dust respirator. Be sure to use an approved/certified respirator or equivalent. Wear appropriate respiratorwhen ventilation is inadequate. Safety glasses.

Section 16: Other Information

References: Not available.

Other Special Considerations: Not available.

Created: 10/10/2005 08:21 PM

Last Updated: 11/06/2008 12:00 PM

The information above is believed to be accurate and represents the best information currently available to us. However, wemake no warranty of merchantability or any other warranty, express or implied, with respect to such information, and we assumeno liability resulting from its use. Users should make their own investigations to determine the suitability of the information fortheir particular purposes. In no event shall ScienceLab.com be liable for any claims, losses, or damages of any third party or forlost profits or any special, indirect, incidental, consequential or exemplary damages, howsoever arising, even if ScienceLab.comhas been advised of the possibility of such damages.

MSDS – ProX Rocket Motor Reload Kits Page 1/6 Version 2.02 Revision Date. 8 Feb 2010

========================================================================= MATERIAL SAFETY DATA SHEET

=========================================================================

ProX Rocket Motor Reload Kits & Fuel Grains ------------------------------------------------------------------------------------------------------------------------------------------------------------------ 1.0 PRODUCT / COMPANY IDENTIFICATION ------------------------------------------------------------------------------------------------------------------------------------------------------------------ Product Name: Pro29, Pro38, Pro54, Pro75, and Pro98 Rocket Motor Reload Kits Synonyms: Rocket Motor Proper Shipping Name: Articles, Explosive, N.O.S. (Ammonium Perchlorate) Part Numbers: Reload kits: P29R-Y-#G-XX, P38R-Y-#G-XX, P54R-Y-#G-XX, P29R-Y-#GXL-XX, P38R-Y-#GXL-XX, P54R-Y-#GXL-XX,

Propellant grains: P75AC-PG-XX, P98AC-PG-XX, P98AC-MB-PG-XX Where: Y = reload type (A = adjustable delay, C = C-slot)

# = number of grains & XX = propellant type

Product Use: Solid fuel motor for propelling rockets Manufacturer: Cesaroni Technology Inc. P.O. Box 246 2561 Stouffville Rd. Gormley, Ont. Canada L0H 1G0 Telephone Numbers: Product Information: 1-905-887-2370 24 Hour Emergency Telephone Number: 1-613-996-6666 (CANUTEC) ------------------------------------------------------------------------------------------------------------------------------------------------------------------ 2.0 COMPOSITION / INFORMATION ON INGREDIENTS ------------------------------------------------------------------------------------------------------------------------------------------------------------------ Propellant Ingredient Name CAS Number Percentage --------------------------------------------------------------------------------- ------------------ ---------------- ----------------- Ammonium Perchlorate .................................................................................. 7790-98-9 40-85 % Metal Powders ................................................................................................ 1-45 % Synthetic Rubber ............................................................................................ 10-30 % Black Powder Ignition pellet Ingredient Name CAS Number Percentage --------------------------------------------------------------------------------- ------------------ ---------------- ----------------- Potassium Nitrate ............................................................................................ 7757-79-1 70-76 % Charcoal .......................................................................................................... n/a 8-18 % Sulphur ............................................................................................................ 7704-34-9 9-20 % Graphite .......................................................................................................... 7782-42-5 trace ------------------------------------------------------------------------------------------------------------------------------------------------------------------ 3.0 HAZARDS IDENTIFICATION ------------------------------------------------------------------------------------------------------------------------------------------------------------------ Emergency Overview:

There articles contain cylinders of ammonium perchlorate composite propellant, encased in inert plastic parts. The forward closure also contains a few grams of black powder. ProX Rocket motor reload kits are classified as explosives, and may cause serious injury, including death if used improperly. All explosives are dangerous and must be handled carefully and used following approved safety procedures under the direction of competent, experienced personnel in accordance with all applicable federal, state and local laws and regulations. Avoid inhaling exhaust products.

MSDS – ProX Rocket Motor Reload Kits Page 2/6 Version 2.02 Revision Date. 8 Feb 2010

General Appearance: Cardboard tubes contain various plastic parts. Inside the plastic tube are cylinders of composite propellant (rocket fuel). The forward closure also contains a small quantity of black powder. All parts are odourless solids.

Potential Health Effects: Eye: Not a likely route of exposure. May cause eye irritation. Skin: Not a likely route of exposure. Low hazard for usual industrial/hobby handling. Ingestion:

Not a likely route of exposure. Inhalation: Not a likely route of exposure. May cause respiratory tract irritation. Do not inhale exhaust products.

--------------------------------------------------------------------------------------------------------------------------------- 4.0 FIRST AID MEASURES --------------------------------------------------------------------------------------------------------------------------------- Eyes:

Immediately flush eyes with plenty of water for at least 15 minutes, occasionally lifting the upper and lower eyelids. Get medical aid.

Skin: Flush skin with plenty of soap and water for at least 15 minutes while removing contaminated clothing and shoes. Get medical aid if irritation develops or persists.

Ingestion: Do NOT induce vomiting. If conscious and alert, rinse mouth and drink 2-4 cupfuls of milk or water.

Inhalation: Remove from exposure to fresh air immediately. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical aid.

Burns: Burns can be treated as per normal first aid procedures. --------------------------------------------------------------------------------------------------------------------------------- 5.0 FIRE FIGHTING MEASURES --------------------------------------------------------------------------------------------------------------------------------- Extinguishing Media:

In case of fire, use water, dry chemical, chemical foam, or alcohol-resistant foam to contain surrounding fire. Exposure Hazards During Fire: Exposure to extreme heat may cause ignition. Combustion Products from Fire:

During a fire, irritating and highly toxic gases may be generated by thermal decomposition or combustion. Fire Fighting Procedures:

Keep all persons and hazardous materials away. Allow material to burn itself out. As in any fire, wear a self-contained breathing apparatus in pressure-demand, MSHA/NIOSH (approved or equivalent), and full protective gear.

Special Instructions / Notes: These articles burn rapidly and generate a significant flame for a short period of time. Black powder is a deflagrating explosive. It is very sensitive to flame and spark and can also be ignited by friction and impact. When ignited unconfined, it burns with explosive violence and will explode if ignited under even slight confinement. Do not inhale exhaust products.

--------------------------------------------------------------------------------------------------------------------------------- 6.0 ACCIDENTAL RELEASE MEASURES --------------------------------------------------------------------------------------------------------------------------------- Safeguards (Personnel): Spills: Clean up spills immediately. Replace articles in packaging and boxes and seal securely. Sweep or scoop up

using non-sparking tools. --------------------------------------------------------------------------------------------------------------------------------- 7.0 HANDLING AND STORAGE --------------------------------------------------------------------------------------------------------------------------------- Handling: Keep away from heat, sparks and flame. Avoid contamination. Do not get in eyes, on skin or on

clothing. Do not taste or swallow. Avoid prolonged or repeated contact with skin. Follow manufacturer’s instructions for use.

MSDS – ProX Rocket Motor Reload Kits Page 3/6 Version 2.02 Revision Date. 8 Feb 2010

Storage: Store in a cool, dry place away from sources of heat, spark or flame. Keep in shipping packaging when not in use.

--------------------------------------------------------------------------------------------------------------------------------- 8.0 EXPOSURE CONTROLS / PERSONAL PROTECTION --------------------------------------------------------------------------------------------------------------------------------- Engineering Controls:

Use adequate explosion proof ventilation to keep airborne concentrations low. All equipment and working surfaces must be grounded.

Personal Protective Equipment: Eyes:

Wear appropriate protective eyeglasses or chemical safety goggles as described by OSHA's eye and face protection regulations in 29 CFR 1910.133 or European Standard EN166.

Skin: Clothing should be appropriate for handling pyrotechnic substances. Clothing:

Clothing should be appropriate for handling pyrotechnic substances. Respirators:

A respirator is not typically necessary. Follow the OSHA respirator regulations found in 29CFR1910.134 or European Standard EN 149. Always use a NIOSH or European Standard EN 149 approved respirator when necessary.

--------------------------------------------------------------------------------------------------------------------------------- 9.0 PHYSICAL AND CHEMICAL PROPERTIES --------------------------------------------------------------------------------------------------------------------------------- Physical State: solid Appearance: rubber cylinders inside plastic parts Odour: none Odour Threshold: Not available. pH: Not available. Vapour Pressure: Not available. Vapour Density: Not available. Viscosity: Not available. Evaporation Rate: Not available. Boiling Point: Not available. Freezing/Melting Point: Not available. Coefficient of water/oil distribution: Not available. Autoignition Temperature: 280°C Flash Point: Not available. Explosion Limits, lower (LEL): Not available. Explosion Limits, upper (UEL): Not available. Sensitivity to Mechanical Impact: unprotected black powder can be ignited by impact Sensitivity to Static Discharge: unprotected black powder can be ignited by static discharge Decomposition Temperature: > 400°C Solubility in water: black powder is soluble in water Specific Gravity/Density: black powder = 1.7-2.1 Propellant = not available Molecular Formula: Not applicable Molecular Weight: Not applicable. --------------------------------------------------------------------------------------------------------------------------------- 10.0 STABILITY AND REACTIVITY --------------------------------------------------------------------------------------------------------------------------------- Chemical Stability:

Stable under normal temperatures and pressures. Conditions to Avoid:

Heat, static electricity, friction, impact Incompatibilities with Other Materials:

Combustible or flammable materials, explosive materials Hazardous Products Of Decomposition:

Oxides of nitrogen Hazardous Polymerization:

Will not occur.

MSDS – ProX Rocket Motor Reload Kits Page 4/6 Version 2.02 Revision Date. 8 Feb 2010

--------------------------------------------------------------------------------------------------------------------------------- 11.0 TOXICOLOGICAL INFORMATION --------------------------------------------------------------------------------------------------------------------------------- Routes of Entry: Skin contact – not likely Skin absorption – not likely Eye contact – not likely Inhalation – not likely Ingestion – not likely Effects of Acute Exposure to Product: No data available Effects of Chronic Exposure to Product: No data available Exposure Limits: Black Powder Pellets Ingredient Name CAS Number OSHA PEL ACGIH TLV --------------------------------------------------- ------------------ ---------------- ------------------ Potassium Nitrate 7757-79-1 not established not established Charcoal n/a not established not established Sulphur 7704-34-9 not established not established Graphite 7782-42-5 2.5 mg/m3 15 mmpct (TWA) Propellant Ingredient Name CAS Number OSHA PEL ACGIH TLV --------------------------------------------------- ------------------ ---------------- ------------------ Ammonium Perchlorate 7790-98-9 not established not established metal powder varies varies Synthetic Rubber not established not established Irritancy of the Product: No data available Sensitization to the Product: No data available Carcinogenicity: Not listed by ACGIH, IARC, NIOSH, NTP, or OSHA Reproductive Toxicity: No data available Teratogenicity: No data available Mutagenicity: No data available Toxically Synergistic Products: No data available LD50: No data available --------------------------------------------------------------------------------------------------------------------------------- 12.0 ECOLOGICAL INFORMATION --------------------------------------------------------------------------------------------------------------------------------- Environmental Data: Ecotoxicity Data: Not determined. EcoFaTE Data: Not determined. --------------------------------------------------------------------------------------------------------------------------------- 13.0 DISPOSAL CONSIDERATIONS --------------------------------------------------------------------------------------------------------------------------------- Product As Sold: Pack firmly in hole in ground with nozzle pointing up. Ignite motor electrically from a safe

distance and wait 5 minutes before approaching. Dispose of spent components in inert trash.

Product Packaging: Dispose of used packaging materials in inert trash. Special Considerations: Consult local regulations about disposal of explosive materials.

MSDS – ProX Rocket Motor Reload Kits Page 5/6 Version 2.02 Revision Date. 8 Feb 2010

--------------------------------------------------------------------------------------------------------------------------------- 14.0 TRANSPORT INFORMATION --------------------------------------------------------------------------------------------------------------------------------- Shipping Information – Canada TDG Classification: Class 1.4 Explosive Proper Shipping Name: Articles, Explosive, N.O.S. (Model Rocket Motors) UN Number: 0351 UN Classification Code: 1.4 C Packing Group: II UN Packing Instruction: 101 Shipping Information - USA / IMO Proper Shipping Name: Articles, Explosive, N.O.S. (Model Rocket Motors) UN Number: 0351 UN Classification Code: 1.4 C DOT / IMO Label: Class 1 – Explosive – Division 1.4C Shipping Information - IATA Proper Shipping Name: Articles, Explosive, N.O.S. (Model Rocket Motors) UN Number: 0351 UN Classification Code: 1.4 C IATA Labels: Class 1 – Explosive – Division 1.4C Cargo Aircraft Only --------------------------------------------------------------------------------------------------------------------------------- 15.0 REGULATORY INFORMATION --------------------------------------------------------------------------------------------------------------------------------- Canada

This product has been classified according to the hazard criteria of the Canadian Controlled Products Regulations (CPR) and the MSDS contains all of the information required by the CPR. WHMIS Classification: Not Controlled (explosive) Domestic Substance List (DSL) Status:

All ingredients are listed on Canada's DSL List. Canadian Explosives Classification: Class 7.2.5 This product is an authorized explosive in Canada.

These products are not considered “Controlled Good” in Canada under the Controlled Goods Regulations. United States of America TSCA Inventory Status:

All ingredients are listed on the TSCA inventory. Hazardous Chemical Lists CERCLA Hazardous Substance (40 CFR 302.4) No SARA Extremely Hazardous Substance (40CFR 355) No SARA Toxic Chemical (40CFR 372.65) No European/International Regulations

The product on this MSDS, or all its components, is included on the following countries’ chemical inventories: EINECS – European Inventory of Existing Commercial Chemical Substances

European Labelling in Accordance with EC Directives Hazard Symbols: Explosive. Risk Phrases:

R 2 Risk of explosion by shock, friction, fire or other sources of ignition. R 11 Highly flammable R 44 Risk of explosion if heated under confinement.

Safety Phrases: S 1/2 Keep locked up and out of the reach of children. S 8 Keep container dry. S 15 Keep away from heat.

S 16 Keep away from sources of ignition -- No smoking.

MSDS – ProX Rocket Motor Reload Kits Page 6/6 Version 2.02 Revision Date. 8 Feb 2010

S 17 Keep away from combustible material. S 18 Handle and open container with care. S 33 Take precautionary measures against static discharges. S 41 In case of fire and/or explosion do not breathe fumes.

--------------------------------------------------------------------------------------------------------------------------------- 16.0 OTHER INFORMATION --------------------------------------------------------------------------------------------------------------------------------- MSDS Prepared by: Regulatory Affairs Department Cesaroni Technology Inc.

P.O. Box 246 2561 Stouffville Rd. Gormley, ON Canada L0H 1G0 Telephone: 905-887-2370 x239 Fax: 905-887-2375 Web Sites: www.cesaronitech.com www.Pro38.com The data in this Material Safety Data Sheet relates only to the specific material or product designated herein and does not relate to use in combination with any other material or in any process. The information above is believed to be accurate and represents the best information currently available to us. However, we make no warranty of merchantability or any other warranty, express or implied, with respect to such information, and we assume no liability resulting from its use. Users should make their own investigations to determine the suitability of the information for their particular purposes. In no way shall the company be liable for any claims, losses, or damages of any third party or for lost profits or any special, indirect, incidental, consequential or exemplary damages, howsoever arising, even if the company has been advised of the possibility of such damages.

The MSDS format adheres to the standards and regulatory requirements of the United States and may not meet regulatory requirements in other countries.

DuPont Teijin Films Page 1 Material Safety Data Sheet

---------------------------------------------------------------------- "MYLAR" POLYESTER FILM (NOT INCLUDING POLYVINYLIDENE CHLORIDE COATED TYPES) MYL045 Revised 27-APR-2004 ---------------------------------------------------------------------- ---------------------------------------------------------------------- CHEMICAL PRODUCT/COMPANY IDENTIFICATION ---------------------------------------------------------------------- Material Identification

Mylar is a registered trademark of DuPont Teijin Films.

Product Use

OSHA Hazard Communication Standard (29 CFR 1910.1200) requirements for Material Safety Data Sheets do not apply to the product described in this information sheet. This product is excluded as an article.

Tradenames and Synonyms (Remarks)

This data sheet covers the following "Mylar" film types: A, A101, A102, A301, A302, A631, A701, A951, AB, AC, AGN1, AGN4, AHS1, ALS1, ALS2, AP, AP101, AR, AT, AWH, AXM401, AXM402, AXM901, B, C, CL, CMA121, CND, DA, DCLF, DL, DL1, DM, DMS, DP, E, E101, E101MR, EB11, EB11P, EB21, EB31, EC, EL, EL21, ETSF, FG90, FG140, FG200, FG250, FG313, FGM90, FT, GA10, GA848, GF, GFX951, HP, HR, HR631, HS, HS2, IHP, J101, J102, J301, J401, J402, J502, J956, JSB102, JXM102SB, JXM901, KB, KL, KL1, KM, LB, LB3, LBJ, LBT, LBT2, LJX181, M461, M462, M577, MSX, MA, MBP, MLB, MLBT, MO, M021, MSX, MT, MTE, MTL, OL, OL3, OL12, OL13, OL22, OLAF, OL12AF, OL13AF, OLAFT, OWF, P25, PB, PRP, PST, REL, RELT, RS, RSX, RSX631, S, SC, SM462, SMVBT, SP, SR, SRL, ST, ST2, SXM121, SXM141, TLX, TLXMR, TTMHT, VBLC, WC, WC11, WC11G, WC22, WOL, XD856, XHDS, XM35, XM35W, XM101, XM123, XM125, XM208AF, XM462MR, XM679, XM679T1MR, XM728WMR, XM841, XM852, XM861, XM918, XMB, XMBLSF, XMDULAM, XMLBH, XMLBH2, XMLD, XMOL60, XMPCL, XPRL, XSM, XSROL, XWOLT, 308, 365, 376, 401, 800, 800C, 808, 811, 813, 814, 816, 820, 822, 823, 834, 840, 841, 844, 845, 850, 851, 852, 854, 864, 890, 891, 7100

This data sheet also covers the following DuPont Teijin Films which are not branded as "Mylar" products: DuPont Teijin Films, types DB, G2, N5, S1, S2, X2, X2I, X2P, X3I

Company Identification

MANUFACTURER/DISTRIBUTOR DuPont Teijin Films U.S. Limited Partnership 1 Discovery Drive P.O. Box 411 Hopewell, VA 23860 USA

MYL045 DuPont Teijin Films Page 2 Material Safety Data Sheet

(CHEMICAL PRODUCT/COMPANY IDENTIFICATION - Continued)

PHONE NUMBERS Product Information : (800) 635-4639 Fax: (804) 530-9867 Transport Emergency : CHEMTREC: 1-800-424-9300

---------------------------------------------------------------------- COMPOSITION/INFORMATION ON INGREDIENTS ---------------------------------------------------------------------- Components

Material CAS Number % Oriented polyester film. May contain a 100 coextrusion layer. Various fillers or additives used to modify the physical appearance and/or surface properties may be present.

Base Film: Polyethylene Terephthalate 25038-59-9 64-100

Coextrusion layer (if present): Isophthalate Copolymer 24938-04-3 8-20

The following Fillers and/or Additives may be present in one or more film types: Barium Sulfate 7727-43-7 <20 Titanium Dioxide 13463-67-7 <20 Poly(Ethylene/Vinyl Acetate) <10 Acrylic Polymer <5 Polypropylene 9003-07-0 <5 Polyvinyl Alcohol 9002-89-5 <5 Silica 7631-86-9 <1 Silicone <1 Carbon Black (only in black films) 1333-86-4 <1 Aluminum 7429-90-5 <1

Components (Remarks)

Material is not known to contain Toxic Chemicals under Section 313 of Title III of the Superfund Amendments and Reauthorization Act of 1986 and 40 CFR part 372.

---------------------------------------------------------------------- HAZARDS IDENTIFICATION ---------------------------------------------------------------------- Emergency Overview

Appearance: Solid film Odor: Odorless

No known health hazards at ambient temperature. Read the entire MSDS for a more thorough evaluation of the hazards.

MYL045 DuPont Teijin Films Page 3 Material Safety Data Sheet

(HAZARDS IDENTIFICATION - Continued)

Potential Health Effects

High temperature operations using "Mylar" Films can produce fumes or vapors of decomposition products of polyethylene terphthalate and isophthalate polymer. The type and quantity of the fumes or vapors will vary based on temperature, time and other variables. These fumes or vapors may cause eye, nose, throat or respiratory irritation, or other effects such as headache.

Molten polymer can cause thermal burns.

Exposure to components used as fillers is not likely as these are encapsulated in the polymer and fully incorporated into the film.

Carcinogenicity Information

The following components are listed by IARC, NTP, OSHA or ACGIH as carcinogens.

Material IARC NTP OSHA ACGIH Carbon Black (only in black films) 2B

---------------------------------------------------------------------- FIRST AID MEASURES ---------------------------------------------------------------------- First Aid

INHALATION

No specific intervention is indicated as the compound is not likely to be hazardous by inhalation.

However, if exposed to fumes from overheating or combustion, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Call a physician if necessary.

SKIN CONTACT

The compound is not likely to be hazardous by skin contact but cleansing the skin after use is advisable.

If molten material gets on skin, cool rapidly with cold water. Do not attempt to remove material from skin. Obtain medical treatment for thermal burn.

EYE CONTACT

In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Call a physician.

INGESTION

MYL045 DuPont Teijin Films Page 4 Material Safety Data Sheet

(FIRST AID MEASURES - Continued)

Ingestion is not an expected route of exposure during normal use of the product. If ingested, consult a physician.

Notes to Physicians

Prolonged eye irritation may occur from pieces of debris sticking to the eyeball or eyelids.

---------------------------------------------------------------------- FIRE FIGHTING MEASURES ---------------------------------------------------------------------- Flammable Properties

Non-metalized films can be combusted only by remaining in contact with flame. If flame source is stationary, non-metalized films will shrink away and self-extinguish. Non-metalized film remaining in contact with flame can continue to burn slowly, dropping flaming liquid which can spread the fire. Metalized films may support combustion if ignited.

Hazardous gases/vapors produced in fire are carbon dioxide, carbon monoxide, organic acids, aldehydes, alcohols.

During processing, film may pick up a strong static charge. Avoid discharge into dust or solvent laden air as a flash fire or explosion may result.

Extinguishing Media

Water, Foam, Dry Chemical, CO2.

Fire Fighting Instructions

Keep personnel removed and upwind of fire. Wear self-contained breathing apparatus. Wear full protective equipment.

---------------------------------------------------------------------- ACCIDENTAL RELEASE MEASURES ---------------------------------------------------------------------- Safeguards (Personnel)

NOTE: Review FIRE FIGHTING MEASURES and HANDLING (PERSONNEL) sections before proceeding with clean-up. Use appropriate PERSONAL PROTECTIVE EQUIPMENT during clean-up.

Spill Clean Up

Sweep up to avoid slipping hazard.

MYL045 DuPont Teijin Films Page 5 Material Safety Data Sheet

---------------------------------------------------------------------- HANDLING AND STORAGE ---------------------------------------------------------------------- Handling (Personnel)

Do not breathe vapors or fumes that may be evolved during processing.

Avoid skin contact with sharp film edges.

Handling (Physical Aspects)

Rolls of film may telescope. Use caution when handling.

Rolled film should be stored at intended processing temperature for approximately 24 hours prior to use.

Plastic packaging materials can pick up static charge. Polyester film rolls packaged with shrinkwrap (or other plastic overwrap) should be opened or unwrapped only in non-process areas where ignition sources such as solvents are not in use or in storage.

Storage

Store away from heat and sources of ignition. Do not store in direct sunlight. Avoid prolonged storage in high or low temperatures. Recommended storage temperatures are 20 F (-7 C) to 100F (38 C).

---------------------------------------------------------------------- EXPOSURE CONTROLS/PERSONAL PROTECTION ---------------------------------------------------------------------- Engineering Controls

General exhaust is acceptable except where overheating can occur during processing. High temperature operations may require use of local exhaust ventilation to keep employee exposure below recommended limits.

Movement of film over metal or rollers will produce a surface static charge on the film. Consider processing design and procedures that will reduce or dissipate this charge, and eliminate the possibility of unwanted electrical discharge to people, equipment and materials.

Personal Protective Equipment

EYE/FACE PROTECTION

Wear safety glasses.

RESPIRATORY PROTECTION

Respirators are not needed for normal use.

MYL045 DuPont Teijin Films Page 6 Material Safety Data Sheet

(EXPOSURE CONTROLS/PERSONAL PROTECTION - Continued)

Where airborne concentrations are expected to exceed exposure limits, a NIOSH approved respirator should be selected based on the form and concentration of the contaminant in air and in accordance with OSHA Respiratory Protection Standard CFR 1910.134.

PROTECTIVE CLOTHING

If there is potential for contact with hot/molten material, wear heat resistant impervious clothing and footwear.

Special protective clothing is not needed for normal use. Gloves are recommended as good industrial practice.

Exposure Guidelines

Applicable Exposure Limits Polyethylene Terephthalate PEL (OSHA) : None Established TLV (ACGIH) : None Established AEL * (DuPont) : 10 mg/m3, 8 Hr. TWA, total dust 5 mg/m3, 8 Hr. TWA, respirable dust

* AEL is DuPont’s Acceptable Exposure Limit. Where governmentally imposed occupational exposure limits which are lower than the AEL are in effect, such limits shall take precedence.

---------------------------------------------------------------------- PHYSICAL AND CHEMICAL PROPERTIES ---------------------------------------------------------------------- Physical Data

Form : Transparent film Color : Colorless to black (depending on film type) Odor : Negligible Melting Point : ~260 C (~500 F) (PET base film - coextrusion layer or coatings may melt at lower temperatures) Solubility in Water : Insoluble Specific Gravity : 1.2-1.4 Vapor Pressure : Negligible @ 20 C (68 F)

---------------------------------------------------------------------- STABILITY AND REACTIVITY ---------------------------------------------------------------------- Chemical Stability

Stable at normal temperatures and storage conditions.

Incompatibility with Other Materials

Strong acids and bases may hydrolyze the film.

MYL045 DuPont Teijin Films Page 7 Material Safety Data Sheet

(STABILITY AND REACTIVITY - Continued)

Decomposition

Combustion can produces carbon oxides and hydrocarbon oxidation products, including organic acids, aldehydes and alcohols.

Polymerization

Polymerization will not occur.

---------------------------------------------------------------------- TOXICOLOGICAL INFORMATION ---------------------------------------------------------------------- Animal Data

Polyethylene Terephthalate Oral ALD: > 10,000 mg/kg in rats

Polyethylene Terephthalate is not a skin irritant, but is a mild eye irritant.

Toxic effects from short exposures by inhalation resulted in no adverse effects.

Toxic effects from short exposures by ingestion resulted in no adverse effects.

Animal testing indicates that Polyethylene Terephthalate does not have carcinogenic, mutagenic, developmental or reproductive effects.

---------------------------------------------------------------------- ECOLOGICAL INFORMATION ---------------------------------------------------------------------- Ecotoxicological Information

AQUATIC TOXICITY:

No information is available. Toxicity is expected to be low based on insolubility in water.

---------------------------------------------------------------------- DISPOSAL CONSIDERATIONS ---------------------------------------------------------------------- Waste Disposal

Preferred options for disposal are (1) recycling, (2) incin- eration with energy recovery, and (3) landfill. The high fuel value of this product makes option 2 very desirable for material that cannot be recycled. Treatment, storage, transportation, and disposal must be in accordance with applicable federal, state/provincial, and local regulations.

MYL045 DuPont Teijin Films Page 8 Material Safety Data Sheet

---------------------------------------------------------------------- TRANSPORTATION INFORMATION ---------------------------------------------------------------------- Shipping Information

DOT Proper Shipping Name : Not regulated

---------------------------------------------------------------------- REGULATORY INFORMATION ---------------------------------------------------------------------- U.S. Federal Regulations

TSCA Inventory Status : In compliance with TSCA Inventory requirements for commercial purposes.

CLEAN AIR ACT STATUS: This product does not contain, and is not manufactured with ozone depleting chemicals as defined in 58 FR 8136, February 11, 1993 (final rule).

State Regulations (U.S.)

CONEG STATUS: All "Mylar" products are compliant with CONEG regulations; the sum of the concentrations of cadmium, chromium, lead and mercury does not exceed 100 ppm. None of these metals is used as an ingredient or processing aid.

SUBSTANCES ON THE PENNSYLVANIA HAZARDOUS SUBSTANCE LIST THAT MAY BE PRESENT AT A CONCENTRATION OF 1% OR MORE (0.01% FOR SPECIAL HAZARDOUS SUBSTANCES): Barium Sulfate; Titanium Oxide (TiO2); Carbon Black (black films only).

SUBSTANCES ON THE NEW JERSEY WORKPLACE HAZARDOUS SUBSTANCE LIST THAT MAY BE PRESENT AT A CONCENTRATION OF 1% OR MORE (0.1% FOR SUBSTANCES IDENTIFIED AS CARCINOGENS, MUTAGENS OR TERATOGENS): Barium Compounds; Titanium Dioxide; Carbon Black (black films only).

CALIFORNIA PROPOSITION 65 STATUS: The products described herein do not contain substances that require a warning pursuant to Propositions 65.

---------------------------------------------------------------------- OTHER INFORMATION ---------------------------------------------------------------------- NFPA, NPCA-HMIS

NFPA Rating Health : 1 Flammability : 1 Reactivity : 0

NPCA-HMIS Rating Health : 0 Flammability : 1 Reactivity : 0

MYL045 DuPont Teijin Films Page 9 Material Safety Data Sheet

(Continued)

Additional Information

MEDICAL USE: CAUTION: Do not use in medical applications involving permanent implantation in the human body. For other medical applications see DuPont CAUTION Bulletin No. H-50102.

----------------------------------------------------------------------

The data in this Material Safety Data Sheet relates only to the specific material designated herein and does not relate to use in combination with any other material or in any process.

Polyester Films MSDS Coordinator 1007 Market St. Room D-6054A Wilmington, DE 19898 302-773-0904

# Indicates updated section.

This information is based upon technical information believed to be reliable. It is subject to revision as additional knowledge and experience is gained.

End of MSDS

MATERIAL SAFETY DATA SHEET PARTALL® PASTE #2

MSDS Number: P02-002 Effective Date: 14 June 2010 Page 1 of 6

SECTION 1: CHEMICAL PRODUCT AND COMPANY IDENTIFICATION PRODUCT NAME PARTALL® Paste #2 GENERIC NAME Wax polishing compound MANUFACTURER REXCO P.O. Box 80996 Conyers, Georgia 30013 USA TRANSPORTATION EMERGENCY:

CHEMTREC (800) 424-9300 U.S.A. (24 hours/day) CHEMTREC (703) 527-3887 International (Collect calls accepted)

CUSTOMER SERVICE AND PRODUCT EMERGENCY: REXCO (800) 888-1060 U.S.A and Canada

REXCO (770) 483-7610 International SECTION 2: COMPOSITION / INFORMATION ON INGREDIENTS COMPONENT CAS NUMBER CONCENTRATION (%) Light Petroleum Distillate 64742-47-8 64 – 72 Paraffin Wax 8002-74-2 18 – 22 Microcrystalline Wax 64742-42-3 8 – 11 Oxidized Ethene Homopolymer 68609-21-2 2 – 3 SECTION 3: HAZARDS IDENTIFICATION NFPA RATING: Health 1, Fire 2, Reactivity 0 HMIS RATING: Health 1, Fire 2, Reactivity 0 0=MINIMAL, 1=SLIGHT, 2=MODERATE, 3=HIGH, 4=EXTREME POTENTIAL HEALTH EFFECTS

EYES Can cause eye irritation. Prolonged or repeated exposure may result in conjunctiva. SKIN May cause skin irritation. Prolonged or repeated exposure may result in defatting, skin

dermatitis. INHALATON Repeated or prolonged exposure may cause central nervous system depression, including

headache, dizziness, loss of coordination, unconsciousness. INGESTION Can cause nausea and vomiting with danger of Chemical Pneumonia.

MATERIAL SAFETY DATA SHEET PARTALL® PASTE #2

MSDS Number: P02-002 Effective Date: 14 June 2010 Page 2 of 6

CHRONIC HEALTH EFFECTS: Possible central nervous system depression and skin dermatitis. SYMPTOMS OF EXPOSURE: Symptoms of exposure through inhalation, ingestion, or direct contact with skin may include nausea, vomiting, diarrhea, irritation of nose, throat, airways, or skin, central nervous system depression – possibly including headache, loss of coordination, drowsiness, fatigue, and unconsciousness – and death in extreme cases. Pre-existing eye, skin, or respiratory disorders may be aggravated by exposure to this product. PRIMARY ROUTES OF ENTRY: Skin contact, skin absorption, eye contact, and inhalation CANCER INFORMATION: Neither this product nor any of its components is listed as a carcinogen or partial carcinogen by the following agencies: the National Toxicology Program, the International Agency for Research on Cancer, and the Occupational Safety and Health Administration. SECTION 4: FIRST AID MEASURES EYES Flush immediately with cold water for 15 minutes and seek medical attention. SKIN Remove contaminated clothing and wash affected area with soap and hot water. If irritation

from contact persists, seek medical attention. Launder contaminated clothing – including shoes – prior to reuse.

INHALATON If light-headed or having difficulty breathing, expose individual to fresh air and/or oxygen. If breathing stops, begin artificial respiration and seek immediate medical attention.

INGESTION Seek immediate medical attention. DO NOT INDUCE VOMITING. If vomiting occurs spontaneously, keep victim’s head below hips to prevent aspiration into lungs. If possible, do not leave victim unattended.

SECTION 5: FIRE FIGHTING MEASURES FLASH POINT / METHOD: >142 °F (>61 °C) / Tagliabue Closed Cup method (TCC)

AUTO IGNITION TEMPERATURE: 440 °F (226 °C)

FLAMMABLE LIMITS IN AIR (% BY VOLUME): LEL Lower 0.9% / UEL Upper 6.0%

FIRE AND EXPLOSION HAZARDS: Low flash point. Keep work areas free of hot metal surfaces and other sources of ignition.

EXTINGUISHING MEDIA: Use dry chemicals, CO2, water fog, water spray, or foam.

FIRE FIGHTING INSTRUCTIONS: Wear a NIOSH-approved self contained breathing apparatus in positive pressure mode and full bunker gear. Water may be unsuitable as an extinguishing media but helpful in keeping adjacent containers cool in order to prevent container rupture. Avoid spreading burning liquid with water used for cooling purposes.

MATERIAL SAFETY DATA SHEET PARTALL® PASTE #2

MSDS Number: P02-002 Effective Date: 14 June 2010 Page 3 of 6

SECTION 6: ACCIDENTAL RELEASE MEASURES IN CASE OF SPILL: Keep sources of ignition and hot metal surfaces isolated from spill. Persons involved in clean-up should wear personal protection equipment. Stop spill at source and prevent from spreading. If spilled as a solid, scrape and then sweep up spilled material. If spilled as a free-flowing liquid, confine spill and allow liquid to solidify prior to clean-up. If run-off occurs, notify proper authorities as required. Place in chemical waste container and dispose of in accordance with local, state, and federal regulations. SECTION 7: HANDLING AND STORAGE Store in a cool, dry location at 90 °F (32 °C) or below and away from open flames, heat, and sparks. Keep work areas free of hot metal surfaces and other sources of ignition. Keep container tightly closed when not in use to prevent drying out of material. Repack only into high-density polyethylene (HDPE). Containers used for repackaging should be thoroughly tested for long-term product compatibility before use. All new containers must exhibit product labels required for proper identification, safety, handling, and storage. Empty containers may contain product residue such as vapors – continue to observe proper handling and storage precautions. SECTION 8: EXPOSURE CONTROLS / PERSONAL PROTECTION EYE PROTECTION: Safety glasses, goggles, or face shield are advised. Eye washes are recommended for work areas.

SKIN PROTECTON: Wear impervious gloves, clothing, and shoes to prevent skin contact. Safety showers are recommended for work areas. Remove contaminated clothing and wash in hot water and soap prior to reuse.

RESPIRATORY PROTECTION: Exposure levels should be kept below the PEL or TLV for this product. If exposure exceeds recommended levels, use of NIOSH-approved cartridge respirator or gas mask is advised. Engineering controls should be implemented if necessary to reduce exposure.

ENGINEERING CONTROLS: Provide sufficient general and/or local exhaust (explosion-proof ventilation) to keep exposure below PEL or TLV. EXPOSURE GUIDELINES COMPONENT OSHA PEL ACGIH TLV Light Petroleum Distillate 100 ppm PEL/TWA 100 ppm TLV/TWA Paraffin Wax None Established None Established Microcrystalline Wax None Established None Established Oxidized Ethene Homopolymer None Established None Established Threshold limit for wax fumes is 2 mg/m3 in air for 8-hour workday. Avoid generation and inhalation of wax fumes. PEL = PERMISSIBLE EXPOSURE LIMITS TLV = THRESHOLD LIMIT VALUE TWA = TIME WEIGHTED AVERAGE (8 HOURS)

MATERIAL SAFETY DATA SHEET PARTALL® PASTE #2

MSDS Number: P02-002 Effective Date: 14 June 2010 Page 4 of 6

SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES APPEARANCE: White or Green Paste Wax SPECIFIC GRAVITY (H2O=1): 0.788 ODOR: Solvent VAPOR PRESSURE (mm Hg): 3.0 BOILING POINT: 310 - 410 °F (154 - 210 °C) VAPOR DENSITY (AIR=1): 1.4 MELTING POINT: 120 °F (48 °C) SOLUBILITY IN WATER: No V.O.C. (BY % CALCUATION): 533 g/L REACTIVITY IN WATER: No V.O.C. = VOLATILE ORGANIC CONTENT SECTION 10: STABILITY AND REACTIVITY STABILITY: Stable

CONDITIONS TO AVOID: Open flames, hot surfaces, or any ignition source.

INCOMPATIBILITY: Incompatible with strong oxidizing agents, strong acids or bases, alkali metals, halogens, and strong alkalis.

HAZARDOUS DECOMPOSITION: Normal combustion forms carbon dioxide and water vapor. Incomplete combustion will produce carbon monoxide and other toxic substances.

HAZARDOUS POLYMERIZATION: Will not occur SECTION 11: TOXICOLOGICAL INFORMATION No data available specific to this product. Following is data as pertains to one or more major ingredients: EYES: Primary Eye Irritation Index (Rabbits): Maximum average score = 3.3 (Maximum score is 110)

SKIN: Primary Skin Irritation Index (Rabbits): 2.2 (Maximum score is 8.0) Acute Dermal LD50 (Rabbit): 2.0 – 4.0 g/kg for similar products

INHALATION: LC50 (Rat): (male and female) > 6.8 mg/L

INGESTION: Acute Oral LD50 (Rat): > 5 g/kg SECTION 12: ECOLOGICAL INFORMATION Product would not be expected to cause damage to the environment and is inherently biodegradable. Product would be expected to biodegrade slowly, depending upon conditions to which it is exposed.

MATERIAL SAFETY DATA SHEET PARTALL® PASTE #2

MSDS Number: P02-002 Effective Date: 14 June 2010 Page 5 of 6

SECTION 13: DISPOSAL CONSIDERATIONS Waste material may be incinerated at an approved facility where permitted under appropriate Federal, State, and Local regulations. SECTION 14: TRANSPORT INFORMATION DOT CLASSIFICATION: This product is not regulated for transportation.

ICAO / IATA CLASSIFICATION: This product is not regulated for transportation.

IMDG CLASSIFICATION: This product is not regulated for transportation. SECTION 15: REGULATORY INFORMATION COMPREHENSIVE ENVIRONMENTAL RESPONSE COMPENSATION AND LIABILITY ACT OF 1980 (CERCLA) Contains no chemicals on the CERCLA hazardous chemicals list.

SUPERFUND AMENDMENTS AND REAUTHORIZATION ACT OF 1986 (SARA) TITLE III SARA 302: Contains no chemicals subject to SARA 302 reporting

SARA 311/312 HAZARD CATEGORIES: Not hazardous

SARA 313: Contains no chemicals subject to SARA 313 reporting

OCCUPATIONAL HEALTH AND SAFETY ADMINISTRATION (OSHA) CLASSIFICATION: Not applicable

CALIFORNIA PROPOSITION 65: Contains no detectable quantities of Proposition 65 chemicals.

WORKPLACE HAZARDOUS MATERIAL INFORMATION SYSTEM (WHMIS) CLASSIFICATION: Not regulated CHEMICAL INVENTORY: This product is not listed on regulatory inventories or listings. Components are either listed on the following chemical inventories or qualify for an exemption: UNITED STATES Toxic Substances Control Act (TSCA) CANADA Canadian Domestic Substance List (DSL) EUROPE European Inventory of Existing Commercial Chemical Substances (EINECS) AUSTRALIA Australian Inventory of Chemical Substances (AICS) JAPAN Existing and New Chemical Substances (ENCS) KOREA Existing Chemicals List (ECL) PHILIPPINES Philippines Inventory of Chemicals and Chemical Substances (PICCS)

MATERIAL SAFETY DATA SHEET PARTALL® PASTE #2

MSDS Number: P02-002 Effective Date: 14 June 2010 Page 6 of 6

SECTION 16: OTHER INFORMATION All information provided in this Material Safety Data Sheet is believed to be accurate and reliable. REXCO makes no warranty of any kind, express or implied, including warranties of merchantability or fitness for a particular purpose, concerning the safe use of this material in your process or in combination with other substances. Users should make their own tests and assessments as to the suitability of this product or the information contained herein for their particular purposes and uses. . Prepared by: REXCO Product Stewardship Department

Revised October 23, 2006

POLYCARBONATE Page 1 of 3 MSDS

MATERIAL SAFETY DATA SHEET I. PRODUCT IDENTIFICATION

PRODUCT NAME: Polycarbonate PHONE NUMBERS: BAYER EMERGENCY: (412) 923-1800 BAYER INFORMATION: 1-800-628-5084 CHEMTREC: 1-800-424-9300

II. PHYSICAL AND CHEMICAL PROPERTIES

APPEARANCE: Solid tint ODOR: Slight PERCENT VOLATILES: N/A MELTING POINT: 428 – 446°F (220-230°C) SOLUBILITY IN WATER: Insoluble SPECIFIC GRAVITY: 1.2

III. STABILITY AND REACTIVITY STABILITY: Stable MATERIALS TO AVOID: None known

IV. EXPOSURE CONTROLS/PERSONAL PROTECTION

VENTILATION: Provide natural or mechanical ventilation to control exposure levels below

airborne exposure limits. Local mechanical exhaust ventilation should be used at sources of air contamination, such as open process equipment, or during purging operations, to capture gases and fumes that may be emitted. Standard reference sources regarding industrial ventilation should be consulted for guidance about adequate ventilation. In the event of thermal decomposition from overheating the product, evacuate the work area, shut down equipment and provide general ventilation to the room prior to reoccupying.

PROTECTIVE EQUIPMENT

SKIN: None required but fabric gloves are recommended when handling molten material

Revised October 23, 2006 Page 2 of 3 IV. EXPOSURE CONTROLS/PERSONAL PROTECTION - continued

EYE: Safety glasses are recommended as a good industrial hygiene and

safety practice.

RESPIRATOR: NIOSH/MSHA – approved dust respirator recommended if the airborne dust concentration is near or exceeds the nuisance dust exposure limits.

ADDITIONAL PROTECTIVE MEASURES:

The greatest potential for injury occurs when working with molten polymeric resins. During this type of operation it is essential that all workers in the immediate area wear eye and skin protection as protection from thermal burns. Purgings should be collected as small flat thin shapes or thin strands to allow for rapid cooling. Precautions should be taken against auto-ignition of hot, thick masses of the plastic. Quench with water. Grinder dust is an exposure hazard. EXPOSURE GUIDELINES:

INGREDIENT AGENCY VALUE Nuisance Dust OSHA-PEL 15mg/m3 Respirable Dust OSHA-PEL 5mg/m3

V. HEALTH HAZARDS IDENTIFICATION ACUTE OR IMMEDIATE EFFECTS SKIN: Contact with hot material will cause thermal burns

EYES: Mechanical irritation to the eyes may occur due to exposure to fines. Eyes may become red and scratchy and may tear.

INHALATION: Toxic gases/fumes given off during burning or thermal decomposition

cause respiratory irritation CHRONIC/CARCINOGENICITY: Not listed as a carcinogen

VI. FIRST AID MEASURES SKIN: Wash affected areas with soap and water. See a physician if thermal burn

occurs EYES: Flush with plenty of lukewarm water. See a physician or ophthalmologist for

follow-up if irritation is present and persists INHALATION: Move to an area free from risk of further exposure. Give oxygen or artificial

respiration as needed. Obtain medical attention

VII. FIRE FIGHTING MEASURES AUTOIGNITION TEMPERATURE: Above 842°F (450°C) ASTM D-1929B

Revised October 23, 2006 Page 3 of 3 VII. FIRE FIGHTING MEASURES - continued

HAZARDOUS PRODUCTS OF COMBUSTION:

Carbon monoxide, carbon dioxide, bisphenol A, diphenyl carbonate, phenol and phenol derivatives. Traces of aliphatic and aromatic hydrocarbons, aldehydes and acids.

EXTINGUISHING MEDIA: Water; carbon dioxide, dry chemical, foam SPECIAL FIRE FIGHTING INSTRUCTIONS/PRECAUTIONS:

Full emergency equipment with self-contained breathing apparatus must be worn by firefighters

VIII. ACCIDENTAL RELEASE MEASURES

SPILL OR RELEASE:

If molten material is spilled, allow it to solidify. Remove material mechanically by a method which minimizes the generation of airborne dust and place in appropriately marked containers.

IX. HANDLING AND STORAGE HANDLING:

When handling flaked material or during secondary operations, vent storage bins, conveyors, dust collectors, etc. ground handling equipment, keep open flames, sparks and heat away from dusty areas. Maintain highest standards of housekeeping to prevent accumulation of dust.

STORAGE:

Max 200°F (93°C) material should be stored in a clean, dry environment in sealed containers. Material must be dried before processing

X. DISPOSAL CONSIDERATIONS

DISPOSAL: Material may be incinerated or landfilled in compliance with Federal, State, Provincial

and Local environmental control regulations.

XI. DISCLAIMER OF EXPRESSED AND IMPLIED WARRANTIES

The information presented in the Material Safety Data Sheet is based on data believed to be accurate as of the date this Material Safety Data Sheet was prepared. HOWEVER, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE, OR ANY OTHER WARRANTY IS EXPRESSED OR IS TO BE IMPLIED REGARDING THE ACCURACY OR COMPLETENESS OF THE INFORMATION PROVIDED ABOVE, THE RESULTS TO BE OBTAINED FROM THE USE OF THIS INFORMATION OR THE PRODUCT, THE SAFETY OF THIS PRODUCT, OR THE HAZARDS RELATED TO ITS USE. No responsibility is assumed for any damage or injury resulting from abnormal use or from any failure to adhere to recommended practices. The information provided above, and the product, are furnished on the condition that the person receiving them shall make their own determination as to the suitability of the product for their particular purpose and on the condition that they assume the risk of their use. In addition, no authorization is given nor implied to practice any patented invention without a license.

Pro75® Instructions, March 2005 revision

Pro75® High-Power Reloadable Rocket Motor Systems

FOR USE ONLY BY CERTIFIED HIGH-POWER ROCKETRY USERS 18 YEARS OF AGE OR OLDER

Sale to persons under 18 years of age is prohibited by Federal law

FLAMMABLE MATERIAL – KEEP AWAY FROM OPEN FLAME, CIGARETTES OR OTHER HEAT SOURCES AT ALL TIMES

USE WITHIN 1 YEAR OF MANUFACTURING DATE TEMPERATURE RANGE: -5 to 30°C Read this BEFORE you start assembly:

If you have any questions or require assistance, please contact your dealer. If you are unable to resolve your questions or problems then please contact the manufacturer directly. Assistance is available Mon – Fri. 9am – 4:30pm at (905) 887-2370. Ask for ProXX motor products technical support.

Read all instructions carefully and be sure you fully understand each step before proceeding with motor assembly.

Inspect the components of your reload kit carefully before you start assembly. DO NOT use any parts that appear damaged or faulty in any way.

Do not tamper with or modify the hardware or reload kit components in any way. Not only will this void all product warranty, it could cause catastrophic failure of your motor system and result in damage to your rocket vehicle, launch equipment and create a hazard to persons or property.

Reload kit components are designed for ONE USE ONLY, and may not be reused. Reuse of any of these components could result in motor failure and will void product warranty.

Follow the safety code and all rules and regulations of your sport rocketry association. Also ensure that you are in compliance with all local, state/provincial, and Federal laws in all activities involving high power rockets and rocket motors.

Parts checklist:

Pro75® Instructions, March 2005 revision

Pro75® hardware components (if used): Reload kit components: Appropriate size of motor case Forward closure Nozzle holder Threaded retaining rings (2)

Case liner (phenolic tube) Nozzle Forward insulator disk P75-ORK (o-ring kit) P75-TSI-KIT (smoke tracking grain/insulator & igniter kit) Propellant grains (check reload kit package for number and type required for your motor)

Assembly instructions

Be sure to follow the correct instructions for the brand of motor hardware you are using!

Step 1 is the same for both brands of hardware.

All o-rings are pre-lubricated at the factory where required.

Three o-rings are supplied in the P75-ORK o-ring kits. The two larger o-rings are used with both Pro75® and RMS™ hardware. The smaller o-ring is only used with Pro75® hardware.

Do not apply lubricant to the grain spacer o-rings, they are for spacing only.

Phenolic and phenolic/paper components such as the nozzle and case liner tube are brittle and can be cracked, broken or otherwise damaged by excessive force or impact. Please be careful during handling and assembly. If you suspect a part has been damaged in any way, STOP and do not proceed with assembly and especially firing until inspected and replaced if necessary.

1. Forward Closure Assembly

1.1. Apply a light coating of o-ring lubricant or grease to the inside of the cavity in the forward closure. Insert the smoke tracking charge insulator into this cavity and ensure it is seated fully.

1.2. Apply a liberal layer of grease or o-ring lubricant to one end of the smoke tracking grain. Be sure the entire face is coated.

1.3. Insert the smoke tracking grain into the smoke tracking charge insulator, coated end first. Push the grain in with sufficient force to fully seat it and spread the lubricant as shown. The excess lubricant will help prevent gas leakage forward as well as protecting the forward closure from heat and combustion products from the smoke tracking charge.

Smoke Tracking

Grain

Step 1.2 Step 1.3Step 1.1

Tracking Charge

Insulator

Forward Closure

Lubricant/Grease

You may now proceed to the remainder of the instructions for your brand of motor hardware. Step 2 is for Pro75® hardware users. Step 3 is for RMS™ hardware users.

Pro75® Instructions, March 2005 revision

2. Motor Assembly: Pro75® Hardware. Before proceeding, inspect the external o-ring grooves on the forward closure and nozzle holder, as well as the internal groove on the nozzle holder. Clean thoroughly if necessary to remove ALL combustion residue and debris. Also ensure that the inside of the motor case has been thoroughly cleaned.

2.1. Check both ends of the phenolic case liner to ensure that the inside ends have been chamfered or deburred. If not, use a hobby knife or coarse sandpaper to remove the sharp inner edge to allow components to be inserted easily.

2.2. Fit the nozzle to one end of the paper/phenolic case liner tube. It may be a snug fit. Push it carefully but with sufficient force to seat the shoulder on the nozzle all the way into the insulator tube.

2.3. Locate the smaller o-ring in the P75-ORK o-ring kit. Fit the o-ring to the internal groove of the nozzle holder. Push the nozzle holder over the nozzle until fully seated. Apply additional lubricant to the nozzle exit section if necessary to facilitate assembly.

2.4. For steps 2.5 – 2.6 work with the nozzle/case liner assembly and motor case horizontally on your work surface.

2.5. Insert one propellant grain into the forward end of the case liner and push it a short way into the tube. Fit one grain spacer o-ring to the top face of the grain, ensuring it sits flat on the end of the grain. Insert the second grain, push it in a short ways, then add another grain spacer, and so on until you have loaded all propellant grains into

the case liner. 2.5.1. There should be sufficient space after the last grain is inserted to fit the

last spacer in place so that it is flush or extends only slightly from the end of the tube. If it extends out by more than 1/3 of its own thickness, remove it and do not use. Only this spacer may be omitted and only if necessary to fit.

2.6. Carefully install the two larger o-rings into the external grooves of the nozzle holder and forward closure. Handle these components with care from this point on so as not to damage or contaminate the o-rings.

2.7. Place the case liner/nozzle assembly on your work surface with the nozzle end down, and slide the motor case down rear end first (end with thrust ring) over the top of the liner towards the nozzle. Note: a light coat of grease on the liner exterior will aid assembly, disassembly and cleanup!

2.8. Lay the motor case assembly down horizontally, and push on the nozzle ring until the assembly is far enough inside the case that the threads are partly exposed and the screw ring can be threaded into the rear of the case. Don’t push on the nozzle itself as you will push it out of the nozzle holder.

Step 2.7

Pro

75

R

Motor Case

NozzlePhenolic Case

Liner

Step 2.1 & 2.2

O-ring ininternal groove

Nozzle Holder

Step 2.3

Grain Grain Spacer

Step 2.5

O-ring inexternal groove

Pro75® Instructions, March 2005 revision

2.9. Screw in the nozzle retaining ring using the supplied wrench, pushing the nozzle/nozzle ring/case liner assembly forward as you proceed. Screw it in only until the retaining ring is exactly even with the end of the motor case - do not thread it in as far as it will go. Then, back the retaining ring out one half of a turn.

2.10. Fit the forward insulating disk to the top of the case liner, checking that the top grain spacer (if used) is still properly in place.

2.11. Verify that the inside of the motor case is clean ahead of the liner assembly before proceeding. Wipe with a clean rag, tissue or wet-wipe if required. Apply a light coat of silicone o-ring lubricant onto this area after cleaning.

2.12. Insert the assembled forward closure into the top of the motor case, pushing it down carefully with your fingers until you can thread in the retaining ring. Thread in the forward retaining ring using the wrench, until you feel it take up a load against the top of the case liner. At this point the ring should be approximately flush with the end of the motor case, or slightly submerged. If it extends out the case at this point by more than about one half a turn, check the nozzle end to make sure the ring is not screwed in too far forward. If so, unscrew the nozzle retaining ring another half turn and screw the forward closure retainer in further.

NOTE: it is best to have the forward closure retaining ring flush or slightly submerged and the nozzle retaining ring protruding by a half turn or so, than vice versa. There is more tolerance for o-ring location at the nozzle end. There will always be some minor variation in the length of internal components due to manufacturing tolerances.

2.13. Skip ahead to Section 4, Preflight preparation.

3. Motor Assembly, RMS™ Hardware. 3.1. Check both ends of the phenolic case liner to ensure

that the inside ends have been chamfered or deburred. If not, use a hobby knife or coarse sandpaper to remove the sharp inner edge to allow components to be inserted easily.

3.2. Fit the nozzle to one end of the paper/phenolic case liner tube. It may be a snug fit. Push it carefully but with sufficient force to seat the shoulder on the nozzle all the way into the insulator tube.

3.3. For steps 3.4 – 3.8 work with the nozzle/case liner assembly and motor case horizontally on your work surface.

P r o 7 5 RCLOCKWISE

Nozzle Retaining

Ring

Wrench

Step 2.9

Pro75 Insulating Disk

Pro98 Insulating Disk

Step 2.10

Lubricant/Grease

Forward Retaining

Ring

CLOCKWISE

Wrench

Step 2.11 & 2.12

NozzlePhenolic Case

Liner

Step 3.2

Pro75® Instructions, March 2005 revision

3.4. Insert one propellant grain into the forward end of the case liner and push it a short way into the tube. Fit one grain spacer o-ring to the top face of the grain, ensuring it sits flat on the end of the grain. Insert the second grain, push it in a short ways, then add another grain spacer, and so on until you have loaded all propellant grains into the case liner.

3.4.1. There should be sufficient space after the last grain is inserted to fit the last spacer in place so that it is flush or extends only slightly from the end of the tube. If it extends out by more than 1/3 of its own thickness, remove it and do not use. Only this spacer may be omitted and only if necessary to fit.

3.5. Slide the completed liner/nozzle/grain assembly into the motor case until the nozzle protrudes about 1/8” from the end of the case. Note: a light coat of grease on the liner exterior will aid assembly, disassembly and cleanup!

3.6. Fit the forward insulating disk to the top of the case liner, checking that the top grain spacer (if used) is still properly in place.

3.7. Place one of the larger pre-lubricated o-rings from the P75-ORK kit into the forward end of the case until it is seated against the forward insulator.

3.8. Thread the completed forward closure into the forward end of the motor case by hand until it is seated against the case. NOTE: There will be considerable resistance to threading in the closure in the last 1/8” to 3/16” of travel, due to compression of the o-ring.

3.9. Hold the motor vertically on your work surface with the forward closure downwards, and push down on the nozzle to ensure the liner/nozzle assembly is seated fully forward.

3.10. Place the other identical o-ring into the groove in the nozzle.

3.11. Thread the aft closure into the motor case until it is seated. It is normal for a small gap (up to about 1/16”) to remain between the closure and the end of the case, due to manufacturing tolerances on internal components. Note: There will be considerable resistance to threading in the closure in the last 1/8” to 3/16” of travel, due to compression of the o-ring.

3.12. Proceed to Section 4, Preflight preparation.

Step 3.4

Grain Spacer

Grain

Motor Case

Step 3.5

1/8" (75mm) 1" (98mm)

Step 3.6

75mm Insulating Disk

98mm Insulating Disk

Buna o-ring (Step 3.10)

Step 3.10 & 3.11

MAX 1/16" Gap

Step 3.7 & 3.8

Buna o-ring (Step 3.7)

Pro75® Instructions, March 2005 revision

4. Preflight Preparation. 4.1. Prepare the rocket’s recovery system, before motor installation if possible.

4.2. Install the motor in your rocket, ensuring that it is securely mounted with a positive means of retention to prevent it from being ejected during any phase of the rocket’s flight.

4.3. IMPORTANT: DO NOT INSTALL THE IGNITER IN THE MOTOR UNTIL YOU HAVE THE ROCKET ON THE LAUNCH PAD, OR IN A SAFE AREA DESIGNATED BY THE RANGE SAFETY OFFICER. Follow all rules and regulations of your rocketry association, and/or the National Fire Protection Association (NFPA) Code 1127 where applicable.

4.4. Install the supplied igniter, ensuring that it travels forward until it is in contact with the forward closure. Securely retain the igniter to the motor nozzle with tape, or (if supplied) the plastic cap, routing the wires through one of the vent holes. Ensure that whatever means you use provides a vent for igniter gases to prevent premature igniter ejection.

4.5. Launch the rocket in accordance with all Federal, State/Provincial, and municipal laws as well as the Safety Code of your rocketry association, as well as NFPA Code 1127 where applicable.

5. Post Flight Cleanup.

Do not try to dismount or disassemble your motor until it has thoroughly cooled down after firing. Some components such as the nozzle may be extremely hot for some time after firing.

Perform motor cleanup as soon as possible after firing, however, as combustion residues are corrosive to motor components, and become very difficult to remove after several hours.

5.1. Unthread and remove the forward and rear closures. Remove the nozzle holder from the nozzle.

5.2. Remove the phenolic tracking smoke charge insulator from the forward closure.

5.3. Remove all o-rings.

5.4. Discard all reload kit components with regular household waste, after they have completely cooled down.

5.5. Use wet wipes, or paper towels or rags dampened with water or vinegar to thoroughly clean all residue, grease etc. off all hardware components. Pay close attention to internal and external o-ring grooves. A cotton swab or small stick of balsa is an excellent tool for cleaning these grooves.

5.6. Apply a light coat of grease or o-ring lubricant to all threaded sections and reassemble threaded components for storage.

MEANS OF DISPOSAL: The propellant grains, smoke tracking charge, and the igniter are extremely flammable and burn with an intense, hot flame. The remainder of the components are inert and may be disposed of with household trash. To destroy the flammable components, dig a shallow hole in the ground in a remote area, away from any buildings, trees, people, or any other combustibles. Place the propellant grains and smoke tracking module in the hole. Install the igniter into the core of one of the propellant grains and secure with tape. Ignite electrically from a minimum distance of 15 meters. Douse any smoldering paper residue and discard. Ensure that you are not in violation of any local or state regulations for this procedure. If in doubt, contact your local fire department. Please direct any questions regarding safe disposal to our technical support number on page one of this document. First Aid: If ingested, induce vomiting. Burns from flames are to be treated as regular burns with normal first aid procedures. In either case, seek medical attention.

Cesaroni Technology Incorporated (“CTI”) certifies that it has exercised reasonable care in the design and manufacture of its products. We do not assume any responsibility for product storage, transportation or usage. CTI shall not be held responsible for any personal injury or property damage resulting from the improper handling, storage or use of their products. The buyer assumes all risks and liabilities and accepts and uses CTI products on these conditions. No warranty either expressed or implied is made regarding Pro75® products, except for replacement or repair, at CTI’s option, of those products which are proven to be defective in manufacture within one (1) year from the date of original purchase. For repair or replacement under this warranty, please contact your point of purchase. Proof of purchase will be required. Your province or state may provide additional rights not covered by this warranty.

Check out our web site at http://www.Pro-X.ca for tech tips, FAQ’s, user feedback and photos, or e-mail us at ProX@cesaroni.net

For technical and warranty inquiries, please contact your Pro75® dealer.

Pro75® is a registered trademark of Cesaroni Technology Incorporated. Patent # US06079202. Other patents pending. Made in Canada.

MATERIAL SAFETY DATA SHEET FORMULA FIVE® MOLD RELEASE WAX

MSDS Number: F5MRW-001 Effective Date: 20 June 2003 Page 1 of 5

SECTION 1: CHEMICAL PRODUCT AND COMPANY IDENTIFICATION PRODUCT NAME FORMULA FIVE® Mold Release Wax GENERIC NAME Wax polishing compound MANUFACTURER REXCO P.O. Box 80996 Conyers, Georgia 30094 USA TRANSPORTATION EMERGENCY:

CHEMTREC (800) 424-9300 U.S.A. (24 hours/day) CHEMTREC (703) 527-3887 International (Collect calls accepted)

CUSTOMER SERVICE AND PRODUCT EMERGENCY: REXCO (800) 888-1060 U.S.A and Canada

REXCO (770) 483-7610 International

SECTION 2: COMPOSITION / INFORMATION ON INGREDIENTS COMPONENT CAS NUMBER CONCENTRATION (%) Light Petroleum Distillate 64742-47-8 64 – 76 Carnauba Wax 8015-86-9 12 – 18 Paraffin Wax 8002-74-2 8 – 12 Dimethylpolysiloxane 63148-62-9 4 – 6 SECTION 3: HAZARDS IDENTIFICATION NFPA RATING: Health 1, Fire 2, Reactivity 0 HMIS RATING: Health 1, Fire 2, Reactivity 0 0=MINIMAL, 1=SLIGHT, 2=MODERATE, 3=HIGH, 4=EXTREME POTENTIAL HEALTH EFFECTS

EYES Can cause eye irritation. Prolonged or repeated exposure may result in conjunctiva. SKIN May cause skin irritation. Prolonged or repeated exposure may result in defatting, skin

dermatitis. INHALATON Repeated or prolonged exposure may cause central nervous system depression, including

headache, dizziness, loss of coordination, unconsciousness. INGESTION Can cause nausea and vomiting with danger of Chemical Pneumonia. CHRONIC HEALTH EFFECTS: Possible central nervous system depression and skin dermatitis.

MATERIAL SAFETY DATA SHEET FORMULA FIVE® MOLD RELEASE WAX

MSDS Number: F5MRW-001 Effective Date: 20 June 2003 Page 2 of 5

SYMPTOMS OF EXPOSURE: Symptoms of exposure through inhalation, ingestion, or direct contact with skin may include nausea, vomiting, diarrhea, irritation of nose, throat, airways, or skin, central nervous system depression – possibly including headache, loss of coordination, drowsiness, fatigue, and unconsciousness – and death in extreme cases. Pre-existing eye, skin, or respiratory disorders may be aggravated by exposure to this product. PRIMARY ROUTES OF ENTRY: Skin contact, skin absorption, eye contact, and inhalation CANCER INFORMATION: Neither this product nor any of its components is listed as a carcinogen or partial carcinogen by the following agencies: the National Toxicology Program, the International Agency for Research on Cancer, and the Occupational Safety and Health Administration. SECTION 4: FIRST AID MEASURES EYES Flush immediately with cold water for 15 minutes and seek medical attention. SKIN Remove contaminated clothing and wash affected area with soap and hot water. If irritation

from contact persists, seek medical attention. Launder contaminated clothing – including shoes – prior to reuse.

INHALATON If light-headed or having difficulty breathing, expose individual to fresh air and/or oxygen. If breathing stops, begin artificial respiration and seek immediate medical attention.

INGESTION Seek immediate medical attention. DO NOT INDUCE VOMITING. If vomiting occurs spontaneously, keep victim’s head below hips to prevent aspiration into lungs. If possible, do not leave victim unattended.

SECTION 5: FIRE FIGHTING MEASURES FLASH POINT / METHOD: >142 °F (>61 °C) / Tagliabue Closed Cup method (TCC)

AUTO IGNITION TEMPERATURE: 440 °F (226 °C)

FLAMMABLE LIMITS IN AIR (% BY VOLUME): LEL Lower 0.9% / UEL Upper 6.0%

FIRE AND EXPLOSION HAZARDS: Low flash point. Keep work areas free of hot metal surfaces and other sources of ignition.

EXTINGUISHING MEDIA: Use dry chemicals, CO2, water fog, water spray, or foam.

FIRE FIGHTING INSTRUCTIONS: Wear a NIOSH-approved self contained breathing apparatus in positive pressure mode and full bunker gear. Water may be unsuitable as an extinguishing media but helpful in keeping adjacent containers cool in order to prevent container rupture. Avoid spreading burning liquid with water used for cooling purposes. SECTION 6: ACCIDENTAL RELEASE MEASURES IN CASE OF SPILL: Keep sources of ignition and hot metal surfaces isolated from spill. Persons involved in clean-up should wear personal protection equipment. Stop spill at source and prevent from spreading. If spilled as a solid, scrape and then sweep up spilled material. If spilled as a free-flowing liquid, confine spill

MATERIAL SAFETY DATA SHEET FORMULA FIVE® MOLD RELEASE WAX

MSDS Number: F5MRW-001 Effective Date: 20 June 2003 Page 3 of 5

and allow liquid to solidify prior to clean-up. If run-off occurs, notify proper authorities as required. Place in chemical waste container and dispose of in accordance with local, state, and federal regulations.

CAUTION! FLOORS COVERED WITH RESIDUAL MATERIAL BECOME EXTREMELY SLIPPERY.

SECTION 7: HANDLING AND STORAGE Store in a cool, dry location at 90 °F (32 °C) or below and away from open flames, heat, and sparks. Keep work areas free of hot metal surfaces and other sources of ignition. Keep container tightly closed when not in use to prevent drying out of material. Repack only into high-density polyethylene (HDPE). Containers used for repackaging should be thoroughly tested for long-term product compatibility before use. All new containers must exhibit product labels required for proper identification, safety, handling, and storage. Empty containers may contain product residue such as vapors – continue to observe proper handling and storage precautions.

SECTION 8: EXPOSURE CONTROLS / PERSONAL PROTECTION EYE PROTECTION: Safety glasses, goggles, or face shield are advised. Eye washes are recommended for work areas.

SKIN PROTECTON: Wear impervious gloves, clothing, and shoes to prevent skin contact. Safety showers are recommended for work areas. Remove contaminated clothing and wash in hot water and soap prior to reuse.

RESPIRATORY PROTECTION: Exposure levels should be kept below the PEL or TLV for this product. If exposure exceeds recommended levels, use of NIOSH-approved cartridge respirator or gas mask is advised. Engineering controls should be implemented if necessary to reduce exposure.

ENGINEERING CONTROLS: Provide sufficient general and/or local exhaust (explosion-proof ventilation) to keep exposure below PEL or TLV. EXPOSURE GUIDELINES COMPONENT OSHA PEL ACGIH TLV Light Petroleum Distillate 100 ppm PEL/TWA 100 ppm TLV/TWA Carnauba Wax None Established None Established Paraffin Wax None Established None Established Dimethylpolysiloxane None Established None Established Threshold limit for wax fumes is 2 mg/m3 in air for 8-hour workday. Avoid generation and inhalation of wax fumes.

PEL = PERMISSIBLE EXPOSURE LIMITS TLV = THRESHOLD LIMIT VALUE TWA = TIME WEIGHTED AVERAGE (8 HOURS) SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES APPEARANCE: Tan Paste Wax SPECIFIC GRAVITY (H2O=1): 0.788 ODOR: Solvent VAPOR PRESSURE (mm Hg): 3.0

MATERIAL SAFETY DATA SHEET FORMULA FIVE® MOLD RELEASE WAX

MSDS Number: F5MRW-001 Effective Date: 20 June 2003 Page 4 of 5

BOILING POINT: 310 - 410 °F (154 - 210 °C) VAPOR DENSITY (AIR=1): 1.4 MELTING POINT: 120 °F (48 °C) SOLUBILITY IN WATER: No V.O.C. (BY % CALCUATION): 533 g/L REACTIVITY IN WATER: No V.O.C. = VOLATILE ORGANIC CONTENT SECTION 10: STABILITY AND REACTIVITY STABILITY: Stable

CONDITIONS TO AVOID: Open flames, hot surfaces, or any ignition source.

INCOMPATIBILITY: Incompatible with strong oxidizing agents, strong acids or bases, alkali metals, halogens, and strong alkalis.

HAZARDOUS DECOMPOSITION: Normal combustion forms carbon dioxide and water vapor. Incomplete combustion will produce carbon monoxide and other toxic substances.

HAZARDOUS POLYMERIZATION: Will not occur SECTION 11: TOXICOLOGICAL INFORMATION No data available specific to this product. Following is data as pertains to one or more major ingredients: EYES: Primary Eye Irritation Index (Rabbits): Maximum average score = 3.3 (Maximum score is 110)

SKIN: Primary Skin Irritation Index (Rabbits): 2.2 (Maximum score is 8.0) Acute Dermal LD50 (Rabbit): 2.0 – 4.0 g/kg for similar products

INHALATION: LC50 (Rat): (male and female) > 6.8 mg/L

INGESTION: Acute Oral LD50 (Rat): > 5 g/kg

SECTION 12: ECOLOGICAL INFORMATION Product would not be expected to cause damage to the environment and is inherently biodegradable. Product would be expected to biodegrade slowly, depending upon conditions to which it is exposed. SECTION 13: DISPOSAL CONSIDERATIONS Waste material may be incinerated at an approved facility where permitted under appropriate Federal, State, and Local regulations.

MATERIAL SAFETY DATA SHEET FORMULA FIVE® MOLD RELEASE WAX

MSDS Number: F5MRW-001 Effective Date: 20 June 2003 Page 5 of 5

SECTION 14: TRANSPORT INFORMATION DOT CLASSIFICATION: This product is not regulated for transportation.

ICAO / IATA CLASSIFICATION: This product is not regulated for transportation.

IMDG CLASSIFICATION: This product is not regulated for transportation. SECTION 15: REGULATORY INFORMATION COMPREHENSIVE ENVIRONMENTAL RESPONSE COMPENSATION AND LIABILITY ACT OF 1980 (CERCLA) Contains no chemicals on the CERCLA hazardous chemicals list.

SUPERFUND AMENDMENTS AND REAUTHORIZATION ACT OF 1986 (SARA) TITLE III SARA 302: Contains no chemicals subject to SARA 302 reporting

SARA 311/312 HAZARD CATEGORIES: Not hazardous

SARA 313: Contains no chemicals subject to SARA 313 reporting

OCCUPATIONAL HEALTH AND SAFETY ADMINISTRATION (OSHA) CLASSIFICATION: Not applicable

CALIFORNIA PROPOSITION 65: Contains no detectable quantities of Proposition 65 chemicals.

WORKPLACE HAZARDOUS MATERIAL INFORMATION SYSTEM (WHMIS) CLASSIFICATION: Not regulated CHEMICAL INVENTORY: This product is not listed on regulatory inventories or listings. Components are either listed on the following chemical inventories or qualify for an exemption: UNITED STATES Toxic Substances Control Act (TSCA) CANADA Canadian Domestic Substance List (DSL) EUROPE European Inventory of Existing Commercial Chemical Substances (EINECS) AUSTRALIA Australian Inventory of Chemical Substances (AICS) JAPAN Existing and New Chemical Substances (ENCS) KOREA Existing Chemicals List (ECL) PHILIPPINES Philippines Inventory of Chemicals and Chemical Substances (PICCS) SECTION 16: OTHER INFORMATION All information provided in this Material Safety Data Sheet is believed to be accurate and reliable. REXCO makes no warranty of any kind, express or implied, including warranties of merchantability or fitness for a particular purpose, concerning the safe use of this material in your process or in combination with other substances. Users should make their own tests and assessments as to the suitability of this product or the information contained herein for their particular purposes and uses. Prepared by: REXCO Product Stewardship Department

Page 1 of 2MSDS for #23850 - ZAP ADHESIVE

Item Numbers: 23850-1001 Page 1 of 2

Page 2 of 2MSDS for #23850 - ZAP ADHESIVE

Item Numbers: 23850-1001 Page 2 of 2

SAFETY DATA SHEETDate Issued: 01/22/2010

MSDS No: Z-Poxy Finishing resin - B (hardener)

Date-Revised: 01/22/2010

Revision No: 1

1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING

PRODUCT DESCRIPTION: Z-Poxy Finishing resin - B (hardener) - PT40

MANUFACTURER

Pacer Technology9420 Santa Anita AvenueRancho Cucamonga CA 91730-6117Emergency Contact: CHEMTRECProduct Stewardship: 800-424-9300Alternate Emergency Phone: 703-527-3887Service Number: 909-987-0550Alternate Customer Service: 800-538-3091

2. COMPOSITION / INFORMATION ON INGREDIENTS

Chemical Name CAS EINECS Content

Benzyl alcohol 100-51-6 202-859-9 20 - 40

2,4,6-TRIS(DIMETHYLAMINOMETHYL)PHENOL 90-72-2 202-013-9 10 - 15

3-AMINOMETHYL-3,5,5-TRIMETHYLCYCLOHEXYLAMINE 2855-13-2 220-666-8 3 - 5

3,6,9-TRIAZAUNDECAMETHYLENEDIAMINE 112-57-2 203-986-2 1 - 10

Bis(dimethylamino)methyl phenol 71074-89-0 3

3. HAZARDS IDENTIFICATION

HAZARD DESIGNATION

"Xn" - Harmful

EMERGENCY OVERVIEW

PHYSICAL APPEARANCE: Light yellow colored viscous liquid.

IMMEDIATE CONCERNS: R20/22: Harmful by inhalation and if swallowed.R36/38: Irritating to eyes and skin.S2: Keep Out of Reach of Children.

POTENTIAL HEALTH EFFECTS

EYES: S24/25: Avoid Contact with skin and eyes.

SKIN: R43: May cause sensitization by skin contact.

INGESTION: Irritating to mouth, throat and stomach.

INHALATION: Irritating to the nose, throat and respiratory tract.

SIGNS AND SYMPTOMS OF OVEREXPOSURE

EYES: Causes eye irritation.

SKIN: R43: May cause sensitization by skin contact.

INGESTION: Ingestion of this material can cause mouth, throat, esophageal, and gastrointestinal tract irritation.

INHALATION: Prolonged or excessive inhalation may cause respiratory tract irritation.

ACUTE TOXICITY: Slightly irritating to eyes and respiratory tracts.

CHRONIC EFFECTS: Irritating to eyes, respiratory system and skin.

Page 1 of 5

SAFETY DATA SHEETDate Issued: 01/22/2010

MSDS No: Z-Poxy Finishing resin - B (hardener)

Date-Revised: 01/22/2010

Revision No: 1

MEDICAL CONDITIONS AGGRAVATED: Pre-existing skin, eye and lung conditions.

ROUTES OF ENTRY: Inhalation, ingestion and skin absorption are major routes of entry.

IRRITANCY: Irritating to eyes, respiratory system and skin.

SENSITIZATION: May cause allergic skin reaction.

WARNING CAUTION LABELS: Harmful. Keep out of Reach of Children.

COMMENTS HEALTH: S46: If swallowed, seek medical advice immediately and show this container or label.

COMMENTS: Contains epoxy constituents. See information supplied by manufacturer.

4. FIRST AID MEASURES

EYES: S26: In case of contact with eyes, rinse immediately with plenty of water and seek medical advice.

SKIN: Irritation occurs upon direct contact. Remove contaminated clothing and wash affected areas with soap andwater.

INGESTION: S46: If swallowed, seek medical advice immediately and show this container or label.

INHALATION: Remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Getmedical attention.

5. FIRE FIGHTING MEASURES

EXTINGUISHING MEDIA: Water spray, foam, carbon dioxide, dry chemicals.

FIRE FIGHTING PROCEDURES: Use water spray to keep fire-exposed containers cool and to knock down vaporswhich may result from product decomposition.

FIRE FIGHTING EQUIPMENT: As in any fire, wear self-contained breathing apparatus pressure-demand,(MSHA/NIOSH approved or equivalent) and full protective gear.

HAZARDOUS DECOMPOSITION PRODUCTS: Carbon monoxide/dioxide in a fire. Ammonia when heated. Irritatingand toxic fumes at elevated temperatures. Nitrogen oxides in a fire, which can react with water vapor to formcorrosive nitric acid (TVL 2ppm). Combustion of product under oxygen-starved conditions can be expected toproduce toxic products including nitriles and amides.

6. ACCIDENTAL RELEASE MEASURES

SMALL SPILL: Clean up spills immediately, observing precautions in Protective Equipment section.

LARGE SPILL: Absorb the liquid and scrub the area with detergent and water. Avoid runoff into storm sewers andditches which lead to waterways.

ENVIRONMENTAL PRECAUTIONS

WATER SPILL: R52/53: Harmful to aquatic organisms, may cause long-term adverse effects in the aquaticenvironment.

7. HANDLING AND STORAGE

GENERAL PROCEDURES: S51: Use only in well-ventilated areas.

HANDLING: Avoid breathing (dust, vapor, mist, gas). Avoid contact with skin, eyes and clothing. Keep container

Page 2 of 5

SAFETY DATA SHEETDate Issued: 01/22/2010

MSDS No: Z-Poxy Finishing resin - B (hardener)

Date-Revised: 01/22/2010

Revision No: 1

closed when not in use.

STORAGE: Store in a cool place in original container and protect from sunlight. Keep away from sources of ignition.

STORAGE TEMPERATURE: Ambient room temperature (70F/21C).

8. EXPOSURE CONTROLS / PERSONAL PROTECTION

ENGINEERING CONTROLS: Use only in a well ventilated area.

PERSONAL PROTECTIVE EQUIPMENT

EYES AND FACE: S36/37/39: Wear suitable protective clothing, gloves and eye/face protection.

SKIN: S24: Avoid contact with skin.

RESPIRATORY: S51: Use only in well-ventilated areas.

PROTECTIVE CLOTHING: S24: Avoid contact with skin. and clothing. Launder contaminated clothing beforereuse.

WORK HYGIENIC PRACTICES: Avoid contact with skin and eyes. Wash thoroughly after handling.

9. PHYSICAL AND CHEMICAL PROPERTIES

FLASHPOINT AND METHOD: 93°C (200°F) Pensky-Martens CC

FLAMMABLE LIMITS: Not Established

Chemical NameFlashPoint(°C)

Benzyl alcohol 200

PHYSICAL STATE: Liquid

ODOR: Ammonia Odor.

APPEARANCE: Pale yellow viscous liquid.

VAPOR PRESSURE: Not Established

VAPOR DENSITY: Not Established

SOLUBILITY IN WATER: Slightly soluble.

EVAPORATION RATE: Not Established

SPECIFIC GRAVITY: 1.040 (water=1)

10. STABILITY AND REACTIVITY

STABLE: Yes

HAZARDOUS POLYMERIZATION: No

STABILITY: Stable.

CONDITIONS TO AVOID: Avoid storage near large masses of epoxy resins.

Page 3 of 5

SAFETY DATA SHEETDate Issued: 01/22/2010

MSDS No: Z-Poxy Finishing resin - B (hardener)

Date-Revised: 01/22/2010

Revision No: 1

HAZARDOUS DECOMPOSITION PRODUCTS: Combustible by-products of carbon monoxide/dioxide, hydrogensulfide and oxides of sulfur.

INCOMPATIBLE MATERIALS: Avoid strong oxidizing agents and amines especially when hot.

11. TOXICOLOGICAL INFORMATION

ACUTE

Chemical Name ORAL LD50

(rat) DERMAL LD50

(rabbit) INHALATION

LC50 (rat)

Benzyl alcohol 1230 2000 1000

EYE EFFECTS: Mildly to moderately irritating.

SKIN EFFECTS: Irritating to skin. May cause allergic skin reaction with prolonged contact.

SENSITIZATION: Irritating to skin. May cause allergic skin reaction with prolonged contact.

12. ECOLOGICAL INFORMATION

ENVIRONMENTAL DATA: Do not flush to sewer.

13. DISPOSAL CONSIDERATIONS

DISPOSAL METHOD: Cure by mixing with equal portion of paired component for non-hazardous solid wastedisposal.

FOR LARGE SPILLS: Dike area to contain spill. Take precautions as necessary to prevent contamination of groundand surface waters. Recover spilled material on adsorbent, such as sawdust or vermiculite, and sweep into closedcontainers for disposal. After all visible traces, including ignitible vapors, have been removed thoroughly wetvacuum the area. Do not flush to sewer. If area of spill is porous, remove as much contaminated earth and gravel,etc. as necessary and place in closed containers for disposal.

PRODUCT DISPOSAL: Do not empty into drains, dispose of this material and its container at hazardous or specialwaste collection point.

14. TRANSPORT INFORMATION

AIR (ICAO/IATA)

SHIPPING NAME: Not restricted

VESSEL (IMO/IMDG)

SHIPPING NAME: Not restricted

15. REGULATORY INFORMATION

EUROPEAN COMMUNITY

EEC LABEL SYMBOL AND CLASSIFICATION

"Xn" - Harmful

Page 4 of 5

SAFETY DATA SHEETDate Issued: 01/22/2010

MSDS No: Z-Poxy Finishing resin - B (hardener)

Date-Revised: 01/22/2010

Revision No: 1

16. OTHER INFORMATION

APPROVED BY: Mary Robles TITLE: Regulatory Affairs Manager

REVISION SUMMARY: Revision #: 1. This MSDS replaces the January 22, 2010 MSDS. Any changes in informationare as follows: In Section 15: EEC Symbol Id.

MANUFACTURER DISCLAIMER:

To the best of our knowledge, the information contained herein is accurate. However, Pacer Technology does notassume any liability for the accuracy or completeness of the information contained herein. Final determination ofsuitability of any material is the sole responsibility of the user. All materials may present unknown hazards andshould be used with caution. Although certain hazards are described herein, we cannot guarantee that these arethe only hazards which exist.

Page 5 of 5

SAFETY DATA SHEETDate Issued: 12/04/2007

MSDS No: Z-Poxy Quick Set Formula - Resin

Date-Revised: 01/22/2010

Revision No: 1

1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING

PRODUCT DESCRIPTION: Z-Poxy Quick Set Formula - Resin - PT36, PT37, PT38

MANUFACTURER

Pacer Technology9420 Santa Anita AvenueRancho Cucamonga CA 91730-6117Emergency Contact: CHEMTRECProduct Stewardship: 800-424-9300Alternate Emergency Phone: 703-527-3887Service Number: 909-987-0550Alternate Customer Service: 800-538-3091

2. COMPOSITION / INFORMATION ON INGREDIENTS

Chemical Name CAS EINECS Content

Bisphenol a/epichlorohydrin resin 25068-38-6 - - 90 - 100

3. HAZARDS IDENTIFICATION

HAZARD DESIGNATION

"Xi" - Irritant

EMERGENCY OVERVIEW

PHYSICAL APPEARANCE: Light yellow colored viscous liquid.

IMMEDIATE CONCERNS: Slightly irritating to eyes and skin.

POTENTIAL HEALTH EFFECTS

EYES: Contact may cause eye irritation.

SKIN: Irritating to skin. May cause allergic skin reaction with prolonged contact.

INHALATION: Causes respiratory tract irritation.

SIGNS AND SYMPTOMS OF OVEREXPOSURE

EYES: Causes eye irritation.

SKIN: Irritating to skin. May cause allergic skin reaction with prolonged contact.

INGESTION: Causes respiratory tract irritation.

MEDICAL CONDITIONS AGGRAVATED: Pre-existing eye and skin disorders or lung allergies may be aggravatedby exposure.

ROUTES OF ENTRY: Direct contact with skin or eyes.

IRRITANCY: Irritating to eyes, respiratory system and skin.

SENSITIZATION: May cause allergic skin reaction.

4. FIRST AID MEASURES

EYES: Immediately flush with plenty of water. After initial flushing, remove any contact lenses and continue flushingfor at least 15 minutes. Have eyes examined and tested by medical personnel.

Page 1 of 4

SAFETY DATA SHEETDate Issued: 12/04/2007

MSDS No: Z-Poxy Quick Set Formula - Resin

Date-Revised: 01/22/2010

Revision No: 1

SKIN: Immediately wash skin with soap and plenty of water. Remove contaminated clothing. Get medical attention ifsymptoms reoccur. Wash clothing before reuse.

INGESTION: If swallowed, do NOT induce vomiting. Give victim a glass of water or milk. Call a physician or poisoncontrol center immediately. Never give anything by mouth to an unconscious person.

INHALATION: Remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Getmedical attention.

5. FIRE FIGHTING MEASURES

EXTINGUISHING MEDIA: Use alcohol foam, carbon dioxide, or water spray when fighting fires involving thismaterial.

FIRE FIGHTING PROCEDURES: Use water spray to keep fire-exposed containers cool and to knock down vaporswhich may result from product decomposition.

FIRE FIGHTING EQUIPMENT: As in any fire, wear self-contained breathing apparatus pressure-demand,(MSHA/NIOSH approved or equivalent) and full protective gear.

HAZARDOUS DECOMPOSITION PRODUCTS: Carbon Dioxide, Carbon Monoxide and other toxic or irritatingcompounds may form when heated to decomposition.

6. ACCIDENTAL RELEASE MEASURES

SMALL SPILL: Clean up spills immediately, observing precautions in Protective Equipment section.

LARGE SPILL: Absorb the liquid and scrub the area with detergent and water. Avoid runoff into storm sewers andditches which lead to waterways.

ENVIRONMENTAL PRECAUTIONS

WATER SPILL: This material is a water pollutant and should be prevented from contaminating soil or fromentering sewage and drainage systems and bodies of water.

7. HANDLING AND STORAGE

GENERAL PROCEDURES: Use with adequate ventilation. Avoid contact with eyes, skin and clothing.

HANDLING: Avoid breathing (dust, vapor, mist, gas). Avoid contact with skin, eyes and clothing. Keep containerclosed when not in use.

STORAGE: Store in a cool place in original container and protect from sunlight. Keep away from sources of ignition.

STORAGE TEMPERATURE: Ambient room temperature (70F/21C).

8. EXPOSURE CONTROLS / PERSONAL PROTECTION

ENGINEERING CONTROLS: Use only in a well ventilated area.

PERSONAL PROTECTIVE EQUIPMENT

EYES AND FACE: For normal conditions, wear safety glasses. Where there is reasonable probability of liquidcontact, wear splash-proof goggles.

SKIN: S24: Avoid contact with skin.

RESPIRATORY: Use only in a well ventilated area.

PROTECTIVE CLOTHING: S24: Avoid contact with skin. and clothing. Launder contaminated clothing before

Page 2 of 4

SAFETY DATA SHEETDate Issued: 12/04/2007

MSDS No: Z-Poxy Quick Set Formula - Resin

Date-Revised: 01/22/2010

Revision No: 1

reuse.

WORK HYGIENIC PRACTICES: Avoid contact with skin and eyes. Wash thoroughly after handling.

9. PHYSICAL AND CHEMICAL PROPERTIES

FLASHPOINT AND METHOD: 249°C (480°F) Pensky-Martens CC

PHYSICAL STATE: Liquid

ODOR: Irritating odor.

APPEARANCE: Light yellow colored viscous liquid.

VAPOR PRESSURE: 0.03 mmHg at 25°C (77°F)

VAPOR DENSITY: Not Applicable

BOILING POINT: > 249°C (500°F)

EVAPORATION RATE: Not Applicable.

SPECIFIC GRAVITY: 1.160 (water=1)

(VOC): Not Applicable.

10. STABILITY AND REACTIVITY

STABLE: Yes

HAZARDOUS POLYMERIZATION: No

STABILITY: Stable.

POLYMERIZATION: Will not occur.

CONDITIONS TO AVOID: Avoid temperatures above (300 ) F (148 ) C.

HAZARDOUS DECOMPOSITION PRODUCTS: Carbon monoxide, aldehydes, acids and other organic substancesmay be formed during combustion (>500F) temperature degradation.

INCOMPATIBLE MATERIALS: Strong acids, oxidizing agents, mineral and organic bases, and especially aliphaticamines.

11. TOXICOLOGICAL INFORMATION

EYE EFFECTS: Mildly to moderately irritating.

SKIN EFFECTS: Irritating to skin. May cause allergic skin reaction with prolonged contact.

12. ECOLOGICAL INFORMATION

ENVIRONMENTAL DATA: Do not flush to sewer.

13. DISPOSAL CONSIDERATIONS

DISPOSAL METHOD: Cure by mixing with equal portion of paired component for non-hazardous solid wastedisposal.

Page 3 of 4

SAFETY DATA SHEETDate Issued: 12/04/2007

MSDS No: Z-Poxy Quick Set Formula - Resin

Date-Revised: 01/22/2010

Revision No: 1

FOR LARGE SPILLS: Dike area to contain spill. Take precautions as necessary to prevent contamination of groundand surface waters. Recover spilled material on adsorbent, such as sawdust or vermiculite, and sweep into closedcontainers for disposal. After all visible traces, including ignitible vapors, have been removed thoroughly wetvacuum the area. Do not flush to sewer. If area of spill is porous, remove as much contaminated earth and gravel,etc. as necessary and place in closed containers for disposal.

PRODUCT DISPOSAL: Do not empty into drains, dispose of this material and its container at hazardous or specialwaste collection point.

14. TRANSPORT INFORMATION

ROAD AND RAIL (ADR/RID)

PROPER SHIPPING NAME: Not Applicable.

AIR (ICAO/IATA)

SHIPPING NAME: Not Applicable.

VESSEL (IMO/IMDG)

SHIPPING NAME: Not Applicable.

15. REGULATORY INFORMATION

EUROPEAN COMMUNITY

EEC LABEL SYMBOL AND CLASSIFICATION

"Xi" - IrritantIRRITANT

16. OTHER INFORMATION

APPROVED BY: Mary Robles TITLE: Regulatory Affairs Manager

REVISION SUMMARY: Revision #: 1. This MSDS replaces the December 04, 2007 MSDS.

MANUFACTURER DISCLAIMER:

To the best of our knowledge, the information contained herein is accurate. However, Pacer Technology does notassume any liability for the accuracy or completeness of the information contained herein. Final determination ofsuitability of any material is the sole responsibility of the user. All materials may present unknown hazards andshould be used with caution. Although certain hazards are described herein, we cannot guarantee that these arethe only hazards which exist.

Page 4 of 4