Construction Details Cont'd.
2.5-4
Carbon Fiber Masts Cont'd.
Tillotson-Pearson purchases the fiber in tow form. The fibers
are then oriented on a loom and woven with very small cross fibers to hold
the tows together in a form which can be handled in production. The
carbon fiber is then precisely impregnated with a special resin
system and laminated on-an aluminum mandrel. Precise application
of heat and pressure is required to cure the composite while yielding
maximum physical properties. The process used by Tillotson-Pearson
is the only one of its kind in existence. All spar manufacturing
is done at the same facility which produces Freedom Yachts FKP structures.
Of course no spar can be produced until it has been properly
designed and engineered to perform in its specific application. The
key to the success and reliability of the Freedom spars is a culmination
of design, manufacture and quality control expertise. Many complex
techniques are used in design which require computer assistance.
Every one foot length of spar is extensively analyzed in the design
process so that laminates can be determined with precision and weights
optimized. Each fastening and hole is analyzed for stress concentra-
tions and potential local failure to assure reliable hardware attach-
ment design.
Before production can begin to build a part, the quality control
team checks all resin, fiber and process set points to assure that
all performance requirements will be met. Skilled operators then
produce the bare shaft of the spar. It is then weighed and sampled
by quality control to check its .physical integrity. The spar then
undergoes final finishing and hardware application after which quality
control will give their final seal of approval.
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