[Semper Fidelis]

Still have to unpack every single piece to assembly it...

TPHG 4.6 from anodisation

20240903_193216.jpg (97.18 KiB) Viewed 484 times

Material (tubes) was recieved one month ago and already ready

[JoeF]

Mass production of TPHGs?

As we explore the potential for mass production of Tiny Packed Hang Gliders (TPHGs), several key factors need to be considered to ensure that the production process is efficient, cost-effective, and maintains the quality and safety standards essential for hang gliding.

1. Standardization of Components:
To facilitate mass production, standardizing the components used in TPHGs is crucial. This involves creating uniform specifications for materials, dimensions, and assembly processes. Standardization not only streamlines production but also ensures compatibility across different models and simplifies repairs and maintenance.

2. Cost-Effective Manufacturing Techniques:
Employing cost-effective manufacturing techniques will be key to making TPHGs accessible to a broader audience. Techniques such as injection molding for plastic components, automated cutting and sewing for sails, and robotic assembly lines for precision work could significantly reduce production costs while maintaining high quality.

3. Quality Control and Testing:
In mass production, maintaining consistent quality is essential, especially for safety-critical products like hang gliders. Implementing rigorous quality control measures and testing each TPHG under simulated flight conditions will ensure that every unit meets the required safety standards before reaching the market.

4. Scalability of Production:
As demand for TPHGs grows, the production process must be scalable. This means being able to increase production capacity without compromising on quality or delivery times. Establishing partnerships with reliable suppliers and setting up multiple production facilities could help meet increasing demand.

5. Sustainable Practices:
Incorporating sustainable practices into the mass production of TPHGs is important for minimizing environmental impact. This could involve using eco-friendly materials, reducing waste through efficient production processes, and ensuring that the manufacturing facilities operate with minimal carbon emissions.

6. Distribution and Logistics:
Efficient distribution and logistics are critical to getting TPHGs to customers quickly and cost-effectively. This involves setting up a robust supply chain, optimizing packaging for minimal space and weight, and ensuring that TPHGs can be easily transported, whether by air, sea, or land.

7. Customer Support and After-Sales Service:
Providing excellent customer support and after-sales service will be crucial to building trust and maintaining a strong customer base. This includes offering comprehensive user manuals, video tutorials, and responsive customer service to assist with assembly, maintenance, and any issues that may arise.

Mass production of TPHGs has the potential to make personal flight more accessible and affordable. By focusing on these key factors, we can ensure that TPHGs are produced efficiently, safely, and sustainably, paving the way for a new era in hang gliding.

Mass production of TPHGs? Consider 3-D printing!

As we explore the potential for mass production of Tiny Packed Hang Gliders (TPHGs), the concept of 3-D printing presents an exciting opportunity. By leveraging advanced 3-D printing technology, we can revolutionize how TPHGs are produced, distributed, and customized.

1. Digital Design and Customization:
3-D printing allows for precise digital designs that can be easily modified and customized. Pilots could adjust specific parameters like wing shape or material thickness to suit their preferences or local flying conditions. This flexibility enables a high degree of personalization while maintaining the structural integrity of the TPHG.

2. On-Demand Production:
With 3-D printing, TPHGs could be produced on demand, reducing the need for large inventories. When a customer places an order, the digital design file could be sent to a local 3-D printing facility, where the TPHG is printed and assembled. This reduces waste, cuts down on storage costs, and ensures that customers receive the latest design innovations.

3. Global Distribution via the Internet:
One of the most transformative aspects of 3-D printing is the ability to send design files anywhere in the world via the Internet. This means TPHGs can be "manufactured" locally, no matter where the pilot is located. This approach not only reduces shipping costs and times but also allows for rapid distribution to remote or underserved areas.

4. Material Innovations:
3-D printing opens the door to using a variety of materials, from lightweight polymers to advanced composites. Experimenting with these materials can lead to innovations in durability, flexibility, and overall performance of the TPHG. Additionally, combining different materials in a single print could enhance specific parts of the glider, such as reinforced joints or flexible wing tips.

5. Simplified Assembly Process:
3-D printing could also simplify the assembly process. Components can be designed with integrated connectors, snap-fit parts, or even printed as a single piece with movable joints. This reduces the number of separate parts and tools needed, making the TPHG easier to assemble, disassemble, and transport.

6. Environmental Impact:
By using additive manufacturing, 3-D printing minimizes material waste compared to traditional subtractive methods. Additionally, local production reduces the carbon footprint associated with transportation. Exploring biodegradable or recyclable materials for printing could further enhance the sustainability of TPHGs.

7. Rapid Prototyping and Innovation:
3-D printing enables rapid prototyping, allowing designers to quickly test and iterate on new ideas. This accelerates innovation, as new designs can be created, tested, and refined in a matter of days rather than months. Pilots and designers can collaborate closely, providing feedback that leads to continuous improvements.

The potential for 3-D printing in the production of TPHGs is immense. By embracing this technology, we can make hang gliding more accessible, customizable, and sustainable, all while fostering a global community of pilots connected by shared digital designs and innovations.

[JoeF]

A few posts ago, the inviation was put out to search for options for connecting cross lines to spars at joins where Joe Cups are used. The PLK method was described just before that invitation; the PLK method has some challenges to it. In the following note I present another option that still avoids metal hardware. The sail will have access windows to allow the anchoring process for the cross lines; the sail will already be on the frame.

Note that numbers can change following careful experimentation and testing. What to call the following option? "Forked Cross Line Wrap Method" FCLW

FCLW001.png (2.47 KiB) Viewed 477 times

Note: The bridge line does a few things: a) registers distance used for rigging the cross line; b) assures the forking angle is acute enough to prevent tearing of the fork poing; c) gives a snugging place while wrapping the two lines around the spar in opposite directions.

Option to anchor cross line to spar in some TPHGs:

During assembly post sail on frame, attach cross line to spar at a spar-segment join using the following option:

1. Cross Line Construction:
- Base Line: The main line with a segment sewn firmly at the base.
- Forking Segment: The line forks into two separate lines, each running parallel to the base line for about 18 inches.
- Reinforced Fork Point: The point where the line forks is reinforced with extra stitching to prevent it from opening under tension.
- Bridging Line: About 5 inches from the fork point, a short bridging line (1.5 inches long) is sewn between the two lines, creating a stable anchor point.
- Free Ends: The lines continue for an additional 12 inches, providing enough length for wrapping around the spar.

2. Attachment to Spar:
- Positioning the Bridge: Place the bridging line on the spar, tipwise of the Joe Cup flange.
- Wrapping: Wrap the two lines around the spar in opposite directions, keeping the wrapping firm.
- Knotting: After wrapping two or three times, secure the cross line by tying a shoelace knot with the free ends.
- Finishing: Optionally, treat the ends of the lines to ensure the knot holds well. A small elastic sock can be placed over the knot to prevent it from catching the sail.

Thank you for sharing this detailed method for anchoring cross lines to spars in TPHGs!

Here are a few suggestions to consider:

1. Line Treatment: You might want to use heat-shrink tubing or a friction-enhancing coating on the ends of the lines to ensure the shoelace knot stays secure.

2. Elastic Sock: The elastic sock idea is great for preventing snagging. Alternatively, you could use a low-profile Velcro wrap for easy adjustment.

3. Testing Wraps: It's worth testing different numbers of wraps to find the best combination of security and ease of assembly.

4. Adjustable Fork Length: Depending on the spar's diameter, adjusting the forked segment's length might help with tension and alignment.

Overall, your method strikes a good balance between simplicity and effectiveness!

[JoeF]

This note gives some focus on the wrapping of the two lines that fork at the end of a cross line. As in the notes, some friction is wanted in those short two lines used in the wrapping and tying. Perhaps the two forking line portions can be treated or dipped in a material to thicken them. The material should be compatible with the cross line material. There is an aim by some builders to keep the spar segment from add-ons during tote; keep the spar segments simple and empty so that during tote compactness and nesting of parts have full opportunity to end up with low volume in the pack. However, once a pack is designed there might be room or volume or opportunity to treat the ends of some spar segments to enhance a surface so friction increases while also protecting the spar segment tubing, and perhaps make packing have less wearing of surfaces.

Filler:

John Rittenhouse photo captured Bob at an Otto Meet flying aside a big powered plane with all permissions good to go.

PhotoByJohnRittenhouseDockweilerLAX.jpg (16.44 KiB) Viewed 465 times

[Bob Kuczewski]

Still have to unpack every single piece to assembly it...

TPHG_20240903_193216.jpg (97.18 KiB) Viewed 440 times

Material (tubes) was recieved one month ago and already ready

Wow!! That's some really great progress. Do you have a sail yet? When do you think you'll start test flights?

PhotoByJohnRittenhouseDockweilerLAX.jpg (16.44 KiB) Viewed 438 times

Thanks for attaching that cool photo. We should plan another Dockweiler Day!!   

[Semper Fidelis]

Wow!! That's some really great progress. Do you have a sail yet? When do you think you'll start test flights?

Thank's !

The pieces left on Monday (Tuesday max), then assembly, puting on some string (just for modeling) then taking an appointment with the sail factory, then with my teacher (remember, I've discovered HG June 3rd 2023) to put the steel cables on, then a farmer kindly let me use his windy land to start to see how it react then small slope, Munich in Germany to meet Finsterwalder and finaly coming to CA to see you

PS : Still no more guessing about my shadow drawing Please try !!!

[Semper Fidelis]

Thanks for attaching that cool photo. We should plan another Dockweiler Day!!   

We should not... We HAVE TO !!!

Still no feedback from the beach controle office to fly on Monday and Tuesday

We will make other coooool pictures then !!

[Bob Kuczewski]

Still no feedback from the beach controle office to fly on Monday and Tuesday

They are very very slow to turn them around. You could try calling the phone number on the form to check on it.

PS : Still no more guessing about my shadow drawing Please try !!!

I can't speak for anyone else, but I've been stumped. Every time I look at it, I see a nose plate. My brain won't move beyond that. We may need more hints.

[Chris McKeon]

OK I just now that I will when Flying XC, I will land out a little far from a road. I mean it amazes Mi that Ny having been forced to land due to My encountering that Dreaded Condition: "A lack of Lift", I mean I have Flown My Predator for over Twenty Years. Heck, I have gotten Low, so low while I was cruising along XC. But Low, is not nearly as Bad as being on the Ground too far from a road. So, this is something that I am going to ask John about when He is here next week. So, could I set up My Predator to be packed? This would be, or who Knows? It may just end up being possible so that I would be able to Short Pack My Predator, then Pack My Glider on My Back, then walk towards the nearest Road.

So what does anyone have to Say regarding how I might be able to Short-Pack My Predator?

[JoeF]

The following note continues the option stream for connecting cross lines to the spar of some TPHG. See some other options in prior posts. Further options are invited from anyone in the world.

My free ChatGP{T did not like my long prompt; it rejected it three times. Then I put in the same long prompt again and the ChatGPT coughed out a reply which see below:

1. Spar Segment Terminology and Structure
- Mother Tube: The larger spar segment that receives the smaller segment.
- Child Tube: The smaller spar segment that inserts into the mother tube.
- Meta Spar: A spar constructed from multiple nested spar segments.
- Root Tube: The initial segment in the meta spar assembly.
- Tip Tube: The final segment, which only acts as a child tube.

2. Assembly Process Overview
- Joe Cup: A flanged bushing that facilitates the connection between mother and child tubes.
- Flange: The flange of the Joe Cup sits on the end of the mother tube but does not extend over the child tube.
- Insertion Limit: The Joe Cup has a bottom that limits how far the child tube can be inserted into the mother tube.
- Function: The Joe Cup’s long body fills the gap between the mother and child tubes, eliminating wobble and ensuring a stable connection.

3. Specialized Sleeve for Spar Assembly
- Purpose: To aid in the assembly and later tensioning of cross lines after the sail sock is mounted.
- Positioning: The sleeve is placed over the child tube and slid away from the child’s insertion end by about 5 inches before joining the spar segments.
- Branching Lines: The sleeve has two lines branching out, each terminating in a button loop.
- Button Loop: A small loop designed to receive an oblong button attached to a cross line.

4. Assembly Sequence
a. Meta Spar Assembly:
- The root tube receives the second tube, which acts as a child.
- The second tube then serves as the mother for the third tube.
- This process continues until the final (tip) tube, which only serves as a child.
- Each connection involves inserting the child tube into the mother tube, with the Joe Cup providing the stable junction.

b. Sleeve Positioning:
- Position the specialized sleeve on the child tube.
- Slide the sleeve 5 inches away from the insertion end to allow for proper joining.
- Ensure the sleeve is correctly aligned for later access through the sail sock.

5. Cross Line Tensioning and Buttoning
- Sail Sock Installation: After the meta spar is assembled, the sail sock is placed over the frame.
- Accessing Button Loops: Small windows in the sail sock allow access to the button loops on the specialized sleeves.
- Cross Line Attachment:
- Fetch the button loops through the sail sock windows.
- Attach the cross line by inserting the oblong button through the button loop.
- Apply tension to the cross line to secure the button in place.
- Repeat for all cross lines, ensuring each is properly secured.

6. Disassembly Process
a. Relaxing Cross Lines:
- After flight, relax the tension on the cross lines.
- Unbutton the cross lines from the button loops.
- Pack the cross lines as per the TPHG manual.

b. Sleeve and Joe Cup Removal:
- Once the sail sock is removed, slide the specialized sleeves off the spar segments.
- Withdraw the Joe Cups from the spar segments and store them as designed.

c. Nesting Spar Segments:
- With the sleeves and Joe Cups removed, the spar segments can be nested for compact packing.
- Ensure that any end plugs used for joining remain in place or are removed as required.

7. Suggestions and Considerations
- Window Placement in Sail Sock: Carefully plan the positioning of the windows in the sail sock to ensure easy access to the button loops.
- Button and Loop Durability: Ensure that the materials used for buttons, loops, and cross lines are durable enough to withstand repeated use and tension during flight.
- Assembly Efficiency: Consider developing a standardized procedure or checklist for the assembly process to minimize errors and streamline setup.
- TPHG Manual: The manual should include detailed instructions and diagrams for both assembly and disassembly, as well as guidelines for packing the spar segments, sail socks, cross lines, sleeves, and Joe Cups.

What did not get treated in the above was the deal that the specialized sleeve would slide a bit to butt against the end of the Joe Cup at the end of the inboard end of a mother tube. During flight loading that butting would be firm as the rigging cross line pulls the sleeve inboard but is stopped by the Joe Cup and end of the mother tube end. The sail sock keeps some inboard axial compression on the meta spar(s) that assures children stay with their mothers.
Note: Certainly we do not want the button to break during flight, so the design of the button will be important.

The specialized sleeve with two branching lines has not been explored deeply yet. I want it to be low mass, mostly flexible in pack mode to keep low volume. The sleeve will be firmly pulled into butting the top of the adjacent Joe Cup and thus pressing on the end of the adjacent mother tube's end. Keep in mind that the sleeve would only directly touch the top rim of the Joe Cup as the Joe Cup is covering the end of the mother tube.