Interorbital Systems Filament Winder

INTERORBITAL: Making Small Robots that Make Giant Robots that Will Fly to the Moon!
This video demonstrates the capabilities of a carbon-composite filament winder built by Interorbital Systems (IOS) in Mojave, CA. The hardware and software were developed completely in-house by IOS engineers. These capabilities are being used to produce lightweight, high-strength propellant tanks for the NEPTUNE family of IOS modular rockets, designed to carry payloads into Earth orbit and to the Moon. The prototype upper-stage tank shown here is built for testing only.
In this video, an aluminum mandrel is wrapped in carbon fiber prepreg tow followed by stretch tape for layer compaction, then loaded into the oven (also manufactured and programmed in-house at IOS) for resin cure. The stretch tape is then removed, revealing the completed pressure vessel (Type 3 COPV). When tested to destruction, this tank experienced material failure at 3 times its projected operating pressure. Success!
Video by Owen Eigenbrot
Copyright © 2017 Interorbital Systems All Rights Reserved
Soundtrack includes excerpts from (listed chronologically):
But Enough About Me, Bill Paxton by Chris Zabriskie is licensed under a Creative Commons Attribution license (creativecommons.org/licenses/...)
Source: chriszabriskie.com/dtv/
Artist: chriszabriskie.com/
Neon, included with iMovie 10.1.5
EDM Detection Mode by Kevin MacLeod is licensed under a Creative Commons Attribution license (creativecommons.org/licenses/...)
Source: incompetech.com/music/royalty-...
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Mario Bava Sleeps In a Little Later Than He Expected To by Chris Zabriskie is licensed under a Creative Commons Attribution license (creativecommons.org/licenses/...)
Source: chriszabriskie.com/vendaface/
Artist: chriszabriskie.com/

[@supergiantbubbles]

This video is blowing my mind. What an awesome machine and software. Mad props to you! And thanks for including the machine sounds :)

[@johnathanlivingstonseagull5524]

Thanks for sharing this.

[@relaxingwithfireandnature3528]

This is satisfying to watch

[@javierdlp]

Pure art!

[@repalmore]

That is exactly the kind of oven that I would build. KISS engineering at it's best. I might use some more iso board on it but that's just me, not saying you should.

[@chautrongan6183]

Thank Sir 👍😊

[@ejicon3099]

Gotta love space technology.

[@harrythegr8898]

Amazing video! And a great build. What control software do you use? Thanks in advance!

[@RBAERO]

Nice video. Question this carbon fiber is not demolded? Is used for reinforce the aluminum vessel?

[@enzov9772]

How long did it take to completely wind that tank?

[@creativecomposites6193]

So the aluminium heats and expands and the carbon is cured,does the aluminium produce stresses in the carbon when it shrinks?

[@jonathanhernandez90]

@threeve weaver How do you seal the ends after curing? The area where the tank is held during winding. I believe one end is for loading and unloading of the working fluid but how about the other?

[@ivanavila4257]

QUE HERMOSO VIDEO

[@mahrezaitm.5162]

Any thoughts if there is a risk of liner buckling due to the applied tension load of winding tapes, which "I assume" will generate a compressive load on the metallic thin liner?

[@deadandbored]

how is the pay out rotation synced to the mandrel rotation when winding over the domes? I noticed the pay out seems to rotate with the mandrel but does it do this proportionally (ie, for every 1 degree of mandrel rotation the pay out rotates 1 degree) or is there a predetermined amount that you guys found through trial and error?

[@rickrack78]

First off, nice looking winder! Good to see hoop coverage past the tangent. Dual drives on the A axis for...? But why a single tow and arduous path to the final payoff roller? Maybe try multiple tows for faster wind and less buildup on the ports. Lots of bridging of tows at the polar openings. Why a hemi dome? Iso -tensoid works well for filament wound vessels. And shrink tape for cosmetics, or consolidation? try peel ply before shrink tape for excess resin and a better finish. And, by the way, sweet oven!

[@mamaslostsoul]

good observation. i assumed its an Iso-tensoid dome. after ur comment, took a close look :-) a qn: doesn't the towpreg need some heating before depositing on the mandrel. else i thought the band may not take the curvature in domes, unlike wet winding !?

[@rickrack78]

Using multiple prepreg tows may exhibit what some call "shingling" on the domes. a combination of tension, heat and proper tow handling before the final payoff will minimize or eliminate the shingling effect.

[@thelazy0ne]

So... How do you get the metal cylinder out?

[@srqjoe3695]

You're winding carbon fiber directly on aluminum. How are you dealing with anodic potential (dielectric corrosion)?

[@RBAERO]

Same question. I think the work life of this vessel is short.

[@gutierrezivan447]

The aluminum is a mold the final part is somehow removed from the aluminum mold

[@grimfpv292]

If it's operating in space, there's little chance of electrolyte intrusion between aluminium and carbon layers.

[@laorent7033]

The aluminium mold expand during curing and retract when room Temp°. As carbon won't move at all. No probkwm of corrosion due to sealant and mold release abd few hours in contact😉

[@santhiswaroop9032]

What is the angle of winding

[@mustafamakina843]

hello how is this machine programmed like cad cam

[@MrTigermishra]

do you make Fiberglass Swimming pool filters bobbin winding machines too? If ye pls reply

[@liamcc9834]

What is the length of this mandrel?

[@user-nu9tn2fd8z]

а сможете показать намотку нити на форму емкости с последующим извлечением внутренней матрицы формы?!

[@saadmirza2727]

You didn't use shrink tape on the domes at all... no compaction there? I'm skeptical that it survived 300% proof pressure without any compaction on the domes.

[@henrikchristensen8458]

fascinating ! how do you get it off the mold when it's finish ??

[@tonythomas951]

In a Type 5 tank how is the mandrel removed?

[@tonythomas951]

threeve weaver, my question was kind of loaded since I work for a company that makes water soluble mandrels. We are Advanced Ceramics Manufacturing and we make mandrels for Boeing and the Space Ship Co. among others. Completely water soluble and non toxic and made in Tucson, Az.

[@Willfisher30]

@@hikefordayz Since the tanks are pressure vessels intended to hold gases, is there a reason they can't be inflated - like a ballon during the curing process? Since Helium can be used to confirm a vacuum, could you just "inflate" the pressure vessel with Helium and begin curing?

[@johnmichaelgavin3617]

@@Willfisher30 No

[@johnathanlivingstonseagull5524]

The working life of these vessels shall be thermo dynamicly unstable with core values largely at or around -20c. Shouldn't we be generating them in that range?

[@quangteodt1]

Hi@@ You ask me what kind of tape is the end of the wrapped in what is it? Does it work as a composite gule? Thanks you.

[@quangteodt1]

threeve weaver thank you for explaining. You ask yourself what kind of ribbon is this name?

[@MrJhuber]

Where can I get one winding machine for pipes and elbows? If someone knows please let me know

[@jasonbridges45]

you probably cant afford it. lol

[@EastyUK]

Do you know what the closest possible angle to 0( or parallel to the tool axis) the layup is? I've read it's around 20 degrees. I wonder with a more complicated setup you could rotate the tool to get longitudinal plies.

[@EastyUK]

Thanks for the reply. Really interesting to consider the various applications.

[@jeffpeachman]

There is an equation for this. Polar_opening_diameter/Mandrel_diameter = sin(theta). Theta is your min wind angle. Realistically I think you can't get that low due to band width.

[@user-nh8tc9po2l]

and the inner tube/cansiter staying inside or how do you remove them?

[@karenslivesmatter2186]

It's the inner part or the tank, if it's just carbon fibre it would rupture from cryogenic temperature

[@massimookissed1023]

OK, but how the hell do you get the form out of the tank ?

[@massimookissed1023]

threeve weaver , thanks, I later saw you'd already answered this question previously. Very neat weaving, - better than Ariane! Keep up the good work. Anything that gets us to space more reliably & cheaper is great :)

[@spkaran1811]

what is the curing oven temperature? let me know... also how to avoid slip during hoop winding? i used link but again the slip occur. how to avoid slip help me how long we need to keep the tank inside curing oven?

[@GreggCesaroni]

Increase your dwell angle at the far ends. Try doing 360 degree dwell. Once it gets to the far ends of the mandrel before the domes, then it’ll wind at 90 for 360 degrees and then go back to hoop angle. Or go to join path. 360 might be overkill but it’s guaranteed to help.

[@gyandevarya1086]

yes

[@aggabus]

How remove mandrel.. Resin?

[@ddegn]

I'm pretty sure the mandrel is part of the tank.

[@user-mv6rl3bf9t]

как с его потом снимают?

[@IamUke]

Totally cool. I was wondering how you got the mandrel out and was hoping to see some kind of magical expand/contract wonder mechanism in action, given how cool the rest of the machinery is. But alas. So how much of a reduction in metal does the CF provide? I bet it's an interesting (and iterative) process to get to the optimum metal thickness for a given spec. Composites are awesome. Thanks for sharing!

[@slevinshafel9395]

not for high temperature due to resin. 300ºC max

[@thiagoepatriciaignacio8698]

I'm interested in this tag

[@itaykal]

Was it designed with FEA? Abaqus I assume (from the guy's hat)

[@Lion_McLionhead]

The helical wrap is so slow, it needs to be 1000x faster if we're going to reach Mars. COPV's needs to come out faster than bullets.

[@tyheify]

How much

[@asupanfootball11]

oh inii yang jatuh di indonesia k-geat aja

[@Berey23]

How do they pop out of mold?

[@creativecomposites6193]

Type 5 ,so the mandrel is like wedges of say a lemon that collapse inside of the vessel and removed from the end?Or maybe a soluble mandrel?

[@candogan6635]

@@creativecomposites6193 how is cad/cam

[@wasoncubotp1133]

Vendisteis el coche para comprar gasolina agotasteis el planeta buscando otros en vez de arreglar este