Wind Tunnel
Lyman-Morse Technologies was sub-contracted by a Maryland based wind tunnel manufacturer to produce a large scale composite wind tunnel to be installed at a university in Massachusetts. While producing large, organically curved parts is common practice for the composites department, holding a dimensional tolerance of +/- 1/8″ across the entire surface for a part this large is not a typical requirement for hull forms and decks. The molds were designed using an “egg crate” construction method that consisted of a strongback, transverse frames, 3 stringers and sheathed in lewon plywood and bendy ply. Where the shape became to tight for bendy ply, foam blocks were CNC cut and inset into the mold on predetermined shelves. In order to reduce tolerance stacking, the frames were designed and machined to a tighter tolerance and sheathing thickness offsets and bend radii were given greater design consideration.