The Production Process
ARTEMIS was produced primarily by hand layup, using countertop sections as caul plates and tool surfaces. Two sheets of honeycomb were bonded to a single sheet of carbon fiber using film adhesive and cured in an oven at 240 F for 1 hour under approximately 2 psi. The core was then allowed to cool, removed from the oven, and bonded by wet lay to four sheets of carbon fiber using epoxy. After gelling under vacuum, the part was allowed to set for 24 hours before the second side was bonded. The seat panel was manufactured in the same way.
The support wraps were made from shelled steel, cut on a band saw and welded to form the underside supports. A 1/2" steel bar was bent and welded to attach the two sides together. Steel was used in place of aluminum due to welding capabilities, and increased the weight of ARTEMIS dramatically.
Cutouts on both the base panel and the seat were necessary to attach the support bars. These cutouts were formed by drilling the corners and then cutting the material between them. After forming the cutouts, the sections were attached and holes were drilled through both the shelled support wraps and the panels, allowing the two to be bolted together. While this did induce stress concentrations on the part, they were not responsible for part failure, as described here.