The fabrication process was split into four different processes: tabletop fabrication, base panel fabrication, strut fabrication, and assembly.
Tabletop Fabrication
The tabletop is a CF/epoxy wet lay-up sandwich panel on a z-shaped glass fiber and cardboard tool. Carbon fiber was laid up with epoxy on the waxed glass fiber tool under vacuum for curing. Cut honeycomb core was then adhered to the sanded inside carbon fiber surface. The tool was then flipped to lay up the last layers of carbon fiber. To finish, a +/- 60° carbon fiber triaxial weave was carefully laid on the top surface.
Base Panel Fabrication
The baseplate is the same CF/epoxy wet lay-up sandwich panel as the tabletop. This was a simple flat wet lay-up panel done on a smooth waxed surface under vacuum for curing. Due to the simple geometry, it was possible to lay up both carbon fiber layers and honeycomb core at one time. This base offers a lightweight, rigid, and smooth surface to support the workspace while allowing the adhesion of assembly components.
Strut Fabrication
The struts are comprised of a wood core with a carbon fiber braided sleeve that was wet out with epoxy while rotating on a filament winder. Due to the high loading (150 lbs.) that these struts are required to carry, wood core was chosen to improve the structural integrity while keeping the weight at a minimum.
Assembly
Our assembly features additional 90 deg CF/epoxy brackets to adhere the scissor lift mechanism between the tabletop and baseplate. Using a threaded rod, welded threaded guide, smooth rods, bearings, and 3D printed wheels, the scissor lift raises and lowers the tabletop workspace by rotating a crank. The current prototype assembly can hold 150 lbs. distributed on the top surface and weighs a total of 19.5 lbs. Rods, nuts, bolts, washers, and bearings were purchased.
