DC-X 1/3 Scale Demonstrator
In 1991 Scaled Composites was selected by McDonnell Douglas Aerospace for the SDIO Single Stage to Orbit demonstrator program. MDA proposed a
lightweight 1/3 scale proof of concept (POC) demonstrator vehicle to validate the rocket powered vertical take off and landing concept.
Scaled was tasked with building the structural aeroshell and aerodynamic control surfaces. The DC-X aeroshell has a height of 62 feet and a maximum
width of 15 feet at the base. Four large hydraulically-actuated flap sections are incorporated into the aeroshell for aerodynamic control during
reentry and landing. A removable nose cone houses the emergency parachute recovery system. Also incorporated into the aeroshell was a "finger ring"
used to restrain and stabilize the fuel tanks during temperature induced expansion and contraction cycles. The retractable landing gear are mounted to
the aeroshell structure and all landing gear loads are reacted through the aeroshell. This structural philosophy would benefit the overall vehicle
both in weight and complexity. Scaled employed low cost tooling methods for fabrication of the DC-X structure. A 1/4 fuselage section male plug was
fabricated from the loft lines supplied by MDA. A single female tool was fabricated from the male plug, and the four graphite/epoxy sandwich panel
sections were fabricated in the female tool. The sections were installed in an assembly fixture and bonded together using in-place graphite/epoxy
laminates. The landing gear receptacles, flap mechanisms and servos were then added. The materials and structural design of the sandwich panel proved
to be capable of maintaining structural integrity under the extreme conditions of the operating environment.
In order to deliver the aeroshell structure in a timely fashion, Scaled did not delay the aeroshell fabrication schedule while waiting for the
resolution of sub-systems integration issues. Scaled sent a structures team to MDA's facility to support the final installation of the subsystems,
which were often performed as minor repairs to the aeroshell structure. This was made possible because the vehicle was not an autoclaved or
high-temperature-cured structure; the low-temperature curing and simple manufacturing process allowed this prototype flexibility. Despite all the post
fabrication modifications, Scaled was able to build the complete aeroshell structure for 300 lb (10%) less than the weight goal. This weight reduction
was instrumental in helping the DC-X vehicle stay within its weight budget.
Scaled was responsible for the emergency parachute recovery system. Scaled selected a parachute vendor and worked closely with that vendor to insure a
timely and cost effective response to the program schedule. Scaled fabricated the necessary parachute test/qualification components and supervised all
the qualification testing for the recovery system. Scaled's team was also dispatched to the White Sands launch facility to support additional
modifications and repairs to the aeroshell structure during the test program.
this one i like but was only a prototype...:S