REEFSTORMER Technical Specification

2018
TECHNICAL SPECIFICATION
Henry Wallace 4227807
Declaration of Originality
Title of Work:
___________________________________________________________________
This dissertation has been written by me. Material from any outside source which I have
used directly or indirectly is acknowledged accurately and I have made clear the extent
to which it has been used.
Name: ____________________________________________________________________
Signed: _______________________________________
Date: _________________________________________
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Henry Wallace
Acknowledgements
For their support and guidance through both this project and my time at the University
of Nottingham, I would like to thank the following people:
Mr. Simon Harrison

Mr. Richard Tew
Mr. Alec Machin
Mr. Chris Bradnum
Mr. Adam Nichols
Mr. Neil White
Mr. Steve Wagstaff
Mr. Adam Gordon-Staples
Mr. Jason Young
For their patience, support and exceptionally honest feedback, I would like to thank the
members of my Wednesday meeting group.
I would also like to thank each and every person who took the time to give me their
thoughts, opinions and advice throughout the course of this project.
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Table of Contents
Henry Wallace 4227807 .................................................................................................................... 0
Declaration of Originality ........................................................................................................................ 1
Acknowledgements ................................................................................................................................. 2
1.0 Introduction ......................................................................................................................................... 6
1.1 Design Brief ...................................................................................................................................... 6
1.2 Product Description ....................................................................................................................... 7
1.3 Illustration ........................................................................................................................................ 8
2.0 Operating Principles & Safety....................................................................................................... 9
2.1 Buoyancy and Archimedes’ Principle ...................................................................................... 9
2.2 Gas Laws and Pressure ..............................................................................................................10
2.3 Decompression .............................................................................................................................. 11
2.4 Air Supply ........................................................................................................................................ 11
3.0 Parts Reference ................................................................................................................................ 12
3.1 Parts Reference............................................................................................................................. 12
3.2 Bill of Materials ............................................................................................................................. 16
4.0 Production Quantities ...................................................................................................................20
5.0 Materials, Manufacture and Cost ................................................................................................ 21
5.1 COMPOSITE_PARTS:................................................................................................................... 21
5.1.1 COMPOSITE_COSTING_METHODOLOGY ..................................................................... 21
5.1.2 FIBREGLASS_PARTS_SPECIFICATION .......................................................................24
ITEM 1.1.2 C_PANEL_BACK.........................................................................................................25
ITEM 1.3 C_PANEL_TOP .............................................................................................................. 26
ITEM 1.4 C_PANEL_BOTTOM ..................................................................................................... 27
ITEM 2.7 O_LEFT_STRUT1 / 4.7 O_RIGHT_STRUT1 ........................................................... 28
ITEM 2.8 O_LEFT_STRUT2 / 4.8 O_RIGHT_STRUT2 ........................................................ 29
ITEM 2.9 O_LEFT_STRUT3 / 4.9 O_RIGHT_STRUT3.........................................................30
ITEM 2.10 O_LEFT_PANEL1 / 4.10 O_RIGHT_PANEL1........................................................ 31
ITEM 2.11 O_LEFT_PANEL2 / 4.11 O_RIGHT_PANEL2 ....................................................... 32
ITEM 2.12 O_LEFT_PANEL3 / 4.12 O_RIGHT_PANEL3 ..................................................... 33
ITEM 2.14 O_LEFT_PANEL5 / 4.14 O_RIGHT_PANEL5..................................................... 34
ITEM 2.15 O_LEFT_PANEL6 / 4.15 O_RIGHT_PANEL6 ..................................................... 35
ITEM 2.16 O_LEFT_PANEL7 / 4.16 O_RIGHT_PANEL7...................................................... 36
ITEM 3 O_LEFT_WING / 5 O_RIGHT_WING .......................................................................... 37
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ITEM 2.5 O_LEFT_PROP_SHROUD_BACK / 4.5 O_RIGHT_PROP_SHROUD_BACK

.............................................................................................................................................................38
ITEM 2.6 O_LEFT_PROP_SHROUD_FRONT / 4.6
O_RIGHT_PROP_SHROUD_FRONT .........................................................................................39
5.2 GENERAL_PARTS:..................................................................................................................... 40
ITEM 1.1.1 DOME ............................................................................................................................. 40
ITEM 5.1.1.3 REAR_CHASSIS ..................................................................................................... 42
ITEM 1.1.4 DOME_SEAL_BACK ..................................................................................................43
ITEM 1.1.5 TOP_CLAMP ............................................................................................................... 44
ITEM 1.1.9.4 C_MOUNT .................................................................................................................49
ITEM 1.1.9.5 C_ARM ...................................................................................................................... 50
ITEM 1.1.10 DOME_SHIELD_F_I / 1.1.11 DOME_SHIELD_F_O............................................ 54
ITEM 1.1.12 FRONT_CLAMP / 1.1.13 FRONT_BAR ................................................................ 55
ITEM 1.2 BOOT_HINGE .................................................................................................................56
ITEM 2.1 O_LEFT_CHASSIS_ELEMENTS / 4.1 O_RIGHT_CHASSIS_ELEMENTS ....... 57
ITEM 2.13 O_LEFT_PANEL4 / 4.13 O_RIGHT_PANEL4 .................................................... 58
5.3 List of Material Suppliers and Quotations .......................................................................... 60
5.3.1 Polyester Resin.................................................................................................................... 60
5.3.2 Woven Fibreglass Mat....................................................................................................... 60
5.3.3 Woven Carbon Fibre Mat ................................................................................................. 60
5.3.4 Stainless Steel Tube and Bar Stock ............................................................................. 60
5.3.5 Stainless Steel Plate ......................................................................................................... 60
5.3.6 Acrylic......................................................................................................................................61
5.3.7 Neoprene ................................................................................................................................61
5.3.8 ABS ...........................................................................................................................................61
5.3.9 Composites Tooling.............................................................................................................61
5.3.10 Injection Moulding Tooling ..............................................................................................61
6.0 Bought-In Components .................................................................................................................62
6.1 SCREWS, WASHERS & NUTS ...................................................................................................62
6.2 OTHER COMPONENTS..............................................................................................................63
ITEM 1.12 TL1000H ........................................................................................................................63
ITEM 1.1.9.3 C_CONSOLE & ITEM 1.1.9.10 C_PIN ..................................................................63
ITEM 1.9 D_RING & 1.10 D_RING_BRACKET ..........................................................................63
ITEM 2.2 O_LEFT_BALLAST_BAG / ITEM 4.2 O_RIGHT_BALLAST_BAG ..................64
ITEM 2.23 HEADLIGHTS / 4.23 HEADLIGHTS .....................................................................64
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ITEM 2.3 O_LEFT_BUOYANCY_BAG / O_RIGHT_BUOYANCY_BAG ...........................64
ITEM 2.4 COPENHAGEN_SUBSEA_VM .................................................................................. 64
ITEM 6.1 CABLE_TIDY ..................................................................................................................65
ITEM 6.2 SUBCONN_16_C........................................................................................................... 65
ITEM 6.3 FNC12220 ENC............................................................................................................. 65
ITEM 6.4 FABER H7 HP80 .......................................................................................................... 66
ITEM 6.5 MILFLEX2 HOSE .......................................................................................................... 66
ITEM 6.6 RS 916-0940 ................................................................................................................. 66
ITEM 6.8 BK3_CAMBAND ........................................................................................................... 67
ITEM 6.9 CABLE ............................................................................................................................. 67
ITEM 6.10 SCUBAPRO_MK25_EVO ......................................................................................... 67
ITEM 6.11 AN-05F AN ................................................................................................................... 68
ITEM 6.13 JUP-20/80 .................................................................................................................. 68
ITEM 9 G1500M .............................................................................................................................. 68
7.0 Assembly ............................................................................................................................................ 69
8.0 Costings ............................................................................................................................................. 72
9.0 Specification Drawings .................................................................................................................. 76
Appendix 1: Composite Costing Model Spreadsheet ................................................................... 77
Appendix 2: Injection Moulding Costing Model Spreadsheet ................................................... 83
Appendix 3: Material Datasheets ......................................................................................................85
Appendix 4: Machine Datasheets ...................................................................................................... 87
Appendix 5: Bought-In Component Datasheets ........................................................................... 89
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1.0 Introduction
1.1 Design Brief
Context
The outdoors industry is in a period of growth, with the extreme activities sector
of the market gaining increasing exposure through traditional as well as social media.
PADI, the leading international diving organisation averages over 900,000 diving
certifications per year1. SCUBA diving and other sub-aqua pastimes are traditionally
expensive sports with high equipment and travel demands for participation. As a result
of this, the SCUBA diving community is characterised by a high level of inexperienced
and newly qualified divers who enjoy diving on the occasional holiday, with a significant
drop off in numbers of advanced divers. The median age for divers is 29, and the market
is 65% male2. The lack of conditioning for diving activity, as well as inexperience in
swimming wearing diving gear means there is opportunity for a product to help new or
non-divers move and experience the underwater environment.
Brief
To design a product to help people who are new to the underwater environment
move around. The new product may be suitable for retail sales, or for tourist experience
providers such as dive shops. The ease of use is paramount, both for the user as a
guided client and as an expert.
Diving is a task which carries an innate amount of risk. The safety of the user is
paramount, and the design of the product must support safe operation, guarding against
physical, electrical, and pressure-related hazards. The solution must comply with the
appropriate electrical safety standards for use underwater in fresh and salt water as well
as having the appropriate strength for water pressure resistance.
Project Objectives
To design a solution which helps users move around underwater for a prolonged period.
To propose a solution which is economically suitable for relatively low volume
production.
To create a desirable, novel product which will impress and invite trial.
Product Goals
Aid mobility through increased speed and duration of travel underwater.
Reduce and prevent diver fatigue over the course of a day of diving.
Facilitate the use and carrying of the diver’s total dive system.
Support the user’s achievement of neutral buoyancy in the water, and positive at the
surface.
To be suitable for use throughout the ‘diving day’, with appropriate power reserves.
To benefit the users within the social context of a dive with buddies and a leader.
1
PADI Worldwide Corporate Statistics (2017) https://www.padi.com/sites/default/files/2017-
07/2017%20PADI%20WW%20Statistics.pdf Accessed January 2018
2
Diving Equipment & Marketing Association Fast Facts: Recreational Scuba Diving and Snorkeling (2017)
http://www.dema.org/store/download.asp?id=7811B097-8882-4707-A160-F999B49614B6 Accessed January 2018
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1.2 Product Description
The Reefstormer is a breathing observational bubble (BOB), which is a type of
submersible vehicle. It consists of an air bubble and accompanying systems. The bubble
has an open bottom into which the operator places their head, leaving the rest of the
body wet, and floating in the water.
The Reefstormer is designed with optimal user experience being held
paramount, with consideration of the physical, cognitive and psychological challenges
associated with the choice to use a personal submersible, as well as the act of doing so.
The key element of this is the dome. The large capacity of the dome helps to avoid
feelings of claustrophobia, by giving the users a space within which they have a clear,
panoramic view, and the freedom to move and change position. The open bottom, with
no restraint also removes many feelings of being trapped which may have otherwise
occurred.
Novice users are the target demographic of the Reefstormer, and the entire
vehicle is tailored to the unique challenges posed by the ideal of a ‘pick up and go’
product. To afford safe and enjoyable use, the piloting of the vehicle is assisted by some
basic automation. Depth transitions and resurfacing is handled by the vehicle adjusting
its buoyancy, leaving the user to pilot on the level. This mitigates risks of inexperienced
users being affected by decompression sickness or nitrogen narcosis.
Designed for the individual and tailored to the rental market, the Reefstormer is
aimed at the experience sector of the tourism industry due to the high cost per vehicle,
and the need for a guide for those new to the underwater environment. Personal sales,
while not discouraged, are expected to be minimal, if any.
The Reefstormer improves on existing BOBs on the market in four ways:

A more comfortable swimming body position, as the dome base size facilitates a
slanted body position. The ride position of existing BOBs is the nonhydrodynamic
forward seated ‘sit-up-and-beg’ position due to the low capacity of their helmet bubbles
requiring the user’s head to be vertical. This also means that in the Reefstormer, the
user floats naturally rather than being held down by shoulder pads on a helmet.
Panoramic views of the underwater environment, due to the large dome size,
with freedom to turn in. The shallow curvature of the dome also provides as clear and
undistorted view as possible which is characteristic of the small domes on existing BOBs
on the market.
Freedom of movement. The change from sitting to swimming positions, as well as
the unique buoyancy conditions within a large dome rather than a helmet, gives users
the freedom to turn, even to pop in and out of the vehicle, and to change ride position at
will. This is also psychologically significant in avoiding panic.
Aesthetics. The Reefstormer has been worked into a reassuring and enticing
product, which looks exciting as an object, and in which the user will look and feel
dynamic. The SCUBA-doo and AquaStar brands which manufacture BOBs have not
managed to cultivate a lifestyle brand aesthetic or following, which makes them more of
a curiosity than activities which encourage true consumer engagement and longevity.
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1.3 Illustration
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2.0 Operating Principles & Safety
2.1 Buoyancy and Archimedes’ Principle
On the Vehicle
The first key operating principle of the Reefstormer is that of buoyancy.
Archimedes’ principle states that when a body is (partially or fully) immersed in a fluid,
there is an upward buoyant force exerted on its centre of mass equal to the weight of
the fluid displaced.
The total volume of the Reefstormer and its bubble, including an allowance for
the ballast bags, is 296079175mm3, or 296L. The weight of seawater is 1.03Kg/L. This
means that the weight of the unit, for it to be able to descend into the water must be
greater than 296*1.03 = 304.88Kg. This is achieved by adding in lead to the ballast bags
in the front outriggers and the rear of the vehicle. Lead’s high density, which is
approximately 11 times that of seawater, means that to offset 10L volume of seawater
displaced, 1L of additional lead is sufficient.
The ascent and descent of the Reefstormer is controlled by buoyancy bags,

attached to the compressed air supply. These inflate and deflate with air, altering the
buoyant force acting on the vehicle, producing a resultant upwards or downwards force
as required. As these bags are not rigid, the effect of water pressure upon them will
allow the air to expand as the vehicle ascends, and compress as it dives deeper, altering
the resultant force. An accelerometer and barometer housed within the electronics
enclosure allow the vehicle to monitor the acceleration and adjust the air volume within
the buoyancy bags accordingly. The volumes of air required are so low that they have a
negligible effect on the air supply longevity, as even 1 litre of extra air in a buoyancy bag
will allow the vehicle to accelerate from 10 metre depth up to the surface at an
excessive and unsafe rate by the time they reach the surface.
On the Passenger
The human body is buoyant in seawater, and that SCUBA divers weight
themselves down to descend below the surface of the water. This is not an issue with a
large capacity BOB, as the passenger is not fully submerged. Only as much of the user is
submerged as is necessary to allow them to float at the surface of the water, as they are
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in a large bubble where if they float higher, they lose buoyancy due to loss of
submersion.
In simple terms, the passenger floats within the dome at the same level as they
float at the surface of the sea.
This means that passengers in the Reefstormer would even be able to wear small
static buoyancy aids on their torso while in the vehicle to improve safety at the surface
of the water.
2.2 Gas Laws and Pressure
A fluid exerts a pressure on all bodies immersed in it.
Pascal’s law states that the pressure exerted on an enclosed fluid is transmitted
undiminished throughout the fluid and acts equally in all directions.
A reasonably intuitive interpretation of this law is that the change in pressure
between two depths is caused by the difference in the weight of the fluid above the
points being measured. A further point is that it may act in all directions – even acting
upwards.
Boyle’s law states: For a fixed mass of gas at constant temperature, the volume
is inversely proportional to the pressure.
pressure*volume=constant
When the Reefstormer is first submerged, the air trapped within the BOB dome is
initially at a pressure of 1 bar - atmospheric pressure at sea level. As the vehicle
descends, the weight of the water above the vehicle increases at a rate of approximately
1 bar per 10 metres of sea water (msw). This acts through the water on the air within the
dome, which compresses proportionally to the increase in pressure.
e.g. 200L of air at 1bar then experiences another 0.1bar of pressure (by descending to
1m below the surface of the sea).
200L*1bar = constant = XL*1.1bar
Therefore:
200*1/1.1=X
X=181.8L
As the air pressure must remain in equilibrium with the water pressure acting upon it,
the air will compress to stay at ambient pressure, and the water level within the dome
will rise.
However, the Reefstormer has an air supply constantly adding air to the system
from a compressed air tank. This air will emerge and decompress to the ambient
pressure of the air within the dome, forcing the water level back down the dome. This
continues until the air forces the water level beyond the level of the dome and escapes,
maintaining a natural equilibrium of air and water pressure with a constant water level
within the dome. The escape point is situated within the confines of the dome, in the
rear panel, causing the air bubbles to escape behind the field of view of the dome.
As the pressure of the air in the bubble is equal to the water pressure acting
upon the lungs, there will be no increase in effort required to breathe at depth. This is
the same principle on which the SCUBA regulator operates.
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2.3 Decompression
Decompression sickness, otherwise known as ‘the bends’ is a condition caused
by complications surrounding dissolved gases leaving solution into bubbles within the
body. This occurs when there is rapid lifting of pressure on the body. This condition is
potentially life threatening, but practically entirely avoidable.
To mitigate the risk of users suffering decompression sickness, traditional
SCUBA diving approaches are taken alongside the low-level automation within the
Reefstormer. Safe ascent rates, as recommended by PADI and SSI range from 9 to 18
metres per minute. As the craft has a maximum depth of 10 metres, this is not a difficult
or restrictive guideline. When instructed by the user that craft is to surface, it will do so
by inflating its buoyancy bags, and allowing the resultant force to accelerate up towards
the surface at a rate no more than 9 metres per minute.
A safety stop at 5 metres for 3 minutes is traditionally done to further decrease
the risk of decompression sickness. This can also be carried out automatically by the
submarine. As the Reefstormer is likely to be used at sites just off the shore, it is highly
likely that much of the sightseeing will be at this depth anyway, and this should not be
an imposition for tourists enjoying their underwater experience.
A third precaution which should be taken is for an experienced dive and
submersible guide, whether in a Reefstormer or SCUBA gear to be present leading all
expeditions. These guides will have experience in safe diving practice such as starting
the dive at the deepest point and slowly ascending throughout to allow gradual
expulsion of dissolved gases from the body. As the Reefstormer is aimed towards the
experience/rental market, guides will absolutely be required for navigational, safety and
emotional support as well.
2.4 Air Supply
The royal navy suggests that an appropriate air delivery rate for helmet divers
undergoing light work is 40L/min. The high-pressure steel air tank specified can hold 85
cubic feet of air at 3442 pound-force per square inch. This converts to 2407L at
240bar. Therefore, the operating time of the air supply is:
Volume of Tank (L) / Flow Rate (L/min) = Operating Time
2407/40 = 60 min
Best practice within diving is to surface with a minimum of 50bar within the tank, to
maintain positive pressure and prevent any moisture entering the tank, which can cause
corrosion and potentially cause problems such as aspiration pneumonia if inhaled
directly from a SCUBA regulator. Therefore, the safety factor of 50/240 should be
applied to the operating time.
60 min - (50 bar/240 bar) * 60 min = 47.5 min safe operating time
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3.0 Parts Reference

3.1 Parts Reference
The structure of the Reefstormer is divided into a central assembly, and two identical,
yet mirrored outrigger subassemblies. The Item numbering follows the following code:
a.b.c.d
Where ‘a’ is the position within the General Arrangement, and each succeeding number
denotes a lower level subassembly position.
Fastener part numbers not noted on reference.
General Arrangement
9 1 3 2
5 4
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Central Assembly
1.1 1.3 1.2
1.4 1.9 1.10 1.12
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Central Structural Assembly
1.1.3 1.1.2 1.1.5 1.1.1 1.1.9.4
1.1.4 1.1.1 1.1.9 1.1.12 1.1.11

0
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Outrigger Assembly
As this assembly is mirrored in both left and right configurations, all parts with
Item Numbers beginning with a 2, will also exist beginning with a 4. These items and, as
such, the entire starboard side outrigger assembly have been costed with their port side
counterparts.
2.2 2.14 2.13 2.10 2.6 2.7 2.3 2.5
2.23 2.15 2.16 2.1 2.8 2.9 2.12 2.4 2.11
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3.2 Bill of Materials

ITEM MAKE
PART NAME DESCRIPTION QTY. PAGE
NO. /BUY
MID DOME SECTION
1 CENTRAL_ASSEMBLY 1 ASSY 69
ASSEMBLY
CENTRAL_STRUCTURAL_ DOME ATTACHMENT TO
1.1 1 ASSY 69
ASSEMBLY CHASSIS
CENTRAL DOME
1.1.1 DOME 1 MAKE 40
COMPONENT
REAR GFRP BODYWORK
1.1.2 C_PANEL_BACK 1 MAKE 25
PANEL
FABRICATED REAR
1.1.3 REAR_CHASSIS 1 MAKE 42
CHASSIS SECTION
NEOPRENE DOME
1.1.4 DOME_SEAL_BACK 1 MAKE 43
CLAMPING SHIELD
DOME REAR OUTER
1.1.5 TOP_CLAMP 1 MAKE 44
CLAMPING MEMBER
1.1.6 SHBS-M8X40-SS ISO 7380 - M8 x 40 --- 40C 12 BUY 62
1.1.7 WASHER ISO 7092 - 8 Washer ISO 7092 - 8 16 BUY 62
1.1.8 ISO 7040-M8-N ISO 7040-M8-N 16 BUY 62
CENTRAL_CONSOLE_
1.1.9 CONSOLE ASSEMBLY 1 ASSY 69
ASSEMBLY
1.1.9.1 C_PIN TRIGGER ASSEMBLY PIN 2 BUY 63
1.1.9.2 C_PAD TRIGGER THUMB PAD 2 MAKE 45
CONTROL CONSOLE
1.1.9.3 C_CONSOLE 1 BUY 63
HOUSING
1.1.9.4 C_MOUNT CONTROL MOUNT BAR 1 MAKE 49
1.1.9.5 C_ARM MAGNETIC TRIGGER ARM 2 MAKE 50
NEOPRENE DOME
1.1.10 DOME_SHIELD_F_I 1 MAKE 54
CLAMPING SEAL
NEOPRENE DOME
1.1.11 DOME_SHIELD_F_O 1 MAKE 54
CLAMPING SEAL
1.1.12 FRONT CLAMP FRONT CLAMPING RING 1 MAKE 55
1.1.13 FRONT_BAR FRONT_CHASSIS_ELEMENT 2 MAKE 55
1.1.14 SHBS-M8X50-SS ISO 7380 - M8 x 50 --- 50C 6 BUY 62
1.2 BOOT_HINGE HINGE 2 MAKE 56
BOOT LID GFRP BODYWORK
1.3 C_PANEL_TOP 1 MAKE 26
PANEL
REAR BASE GFRP
1.4 C_PANEL_BOTTOM 1 MAKE 27
BODYWORK PANEL
1.5 WASHER ISO 7091 - 6 Washer ISO 7091 - 6 4 BUY 62
1.6 SHBS-M6X20-SS ISO 7380 - M6 x 20 --- 20C 2 BUY 62
1.8 ISO 7042-M6-N ISO 7042-M6-N 2 BUY 62
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1.9 D_RING_BRACKET 316SS D RING BRACKET 2 BUY 63
1.10 D_RING 6X30MM A4-AISI D RING 2 BUY 63
1.12 TL-1000-H TOGGLE CLAMP 1 BUY 63
OUTRIGGER_LEFT_ PORT SIDE OUTRIGGER
2 1 ASSY 70
ASSEMBLY ASSEMBLY
O_LEFT_CHASSIS_ OUTRIGGER SUPPORT
2.1 1 MAKE 57
ELEMENTS STRUCTURES
BAG CONTAINING LEAD
2.2 O_LEFT_BALLAST_BAG 1 BUY 64
BALLAST
2.3 O_LEFT_BUOYANCY_BAG INFLATING LIFT BAG 1 BUY 64
COPENHAGEN_SUBSEA_ RIM DRIVEN THRUSTER
2.4 1 BUY 64
VM MODULE
O_LEFT_PROP_SHROUD_ CARBON FINISH REAR
2.5 1 MAKE 38
BACK PROPELLOR SHROUD
O_LEFT_PROP_SHROUD_ CARBON FINISH FRONT
2.6 1 MAKE 39
FRONT PROPELLOR SHROUD
STRUCTURAL REINFORCED
2.7 O_LEFT_STRUT1 1 MAKE 28
GFRP STRUT
GFRP STRUT
GFRP STRUT
2.10 O_LEFT_PANEL1 GFRP BODYWORK PANEL 1 MAKE 31
CARBON FINISH BASE
2.12 O_LEFT_PANEL3 1 MAKE 33
PANEL
2.13 O_LEFT_PANEL4 CLEAR SIDE PANEL 1 MAKE 58
TAPPEX HIMOULD M6
2.17 M6_HIMOULD_INSERT 10 BUY
THREADED INSERT
2.23 HEADLIGHTS HEADLIGHT ASSEMBLIES 1 BUY 64
LEFT SIDE GFRP
3 O_LEFT_WING 1 MAKE 37
BODYWORK PANEL
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OUTRIGGER_RIGHT_ STARBOARD SIDE

4 1 ASSY 70
ASSEMBLY OUTRIGGER ASSEMBLY
O_RIGHT_CHASSIS_ OUTRIGGER SUPPORT
4.1 1 MAKE 57
ELEMENTS STRUCTURES
BAG CONTAINING LEAD
4.2 O_RIGHT_BALLAST_BAG 1 BUY 64
BALLAST
4.3 O_RIGHT_BUOYANCY_BAG INFLATING LIFT BAG 1 BUY 64
RIM DRIVEN THRUSTER
4.4 COPENHAGEN_SUBSEA_VM 1 BUY 64
MODULE
O_RIGHT_PROP_SHROUD_ CARBON FINISH REAR
4.5 1 MAKE 38
BACK PROPELLOR SHROUD
O_RIGHT_PROP_SHROUD_ CARBON FINISH FRONT
4.6 1 MAKE 39
FRONT PROPELLOR SHROUD
4.7 O_RIGHT_STRUT1 1 MAKE 28
GFRP STRUT
GFRP STRUT
GFRP STRUT
4.10 O_RIGHT_PANEL1 GFRP BODYWORK PANEL 1 MAKE 31
CARBON FINISH BASE
4.12 O_RIGHT_PANEL3 1 MAKE 33
PANEL
4.13 O_RIGHT_PANEL4 CLEAR SIDE PANEL 1 MAKE 58
TAPPEX HIMOULD M6
4.17 M6_HIMOULD_INSERT 10 BUY 63
THREADED INSERT
4.23 HEADLIGHTS HEADLIGHT_ASSEMBLIES 1 BUY 64
5 O_RIGHT_WING RIGHT SIDE GFPR PANEL 1 MAKE 37
6 SYSTEMS_ASSEMBLY AIR_AND_POWER_SYSTEMS 1 ASSY 71
CABLING RETENTION
6.1 CABLE_TIDY 1 BUY 65
STRAP
SUBCONN 16 PIN
6.2 SUBCONN_16_C 1 BUY 65
UNDERWATER CONNECTOR
12V 22AH LEAD ACID
6.3 FNC12220 ENC BATTERY UNDERWATER 1 BUY 65
ENCLOSURE
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HIGH PRESSURE DIVING
6.4 FABER H7 HP80 1 BUY 66
CYLINDER
6.5 MILFLEX2 HOSE AIR ROUTING TUBING 3 BUY 66
6.6 RS 916-0940 CVPU NON-RETURN VALVE 1 BUY 66
SUBCONN 16 PIN
6.7 SUBCONN_16_C 1 BUY 65
UNDERWATER CONNECTOR
SCUBA TANK RETAINING
6.8 BK3_CAMBAND 1 BUY 67
CAMBELT
6.9 CABLE POWER CABLE 1 BUY 67
SCUBAPRO FIRST STAGE
6.10 SCUBAPRO_MK25_EVO 1 BUY 67
REGULATOR
IP68 DIECAST NEMA
6.11 AN-05F AN 1 BUY 68
ENCLOSURE
INGENIA JUPITER DIGITAL
6.13 JUP 20/80 1 BUY 68
SERVO DRIVE JUP-20/80
7 WASHER ISO 7092 - 8 Washer ISO 7092 - 8 8 BUY 62
8 ISO 4014 - M8 X 40 X 22-N ISO 4014 - M8 x 40 x 22-N 6 BUY 62
GALVION ELEMENT
9 G1500M 2 BUY 68
SACRIFICIAL ANODE
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4.0 Production Quantities

The market for the Reefstormer is small, and varying regional differences in
specification will be required. As such, the production must be on a combination of make
to order and assemble to order systems.
Production methods and costings have been based on a 1000 unit production
run, this is expected to occur over a minimum 10 year period. The flexibility of the low
volume processes being specified does, however, lead to the ability to scale production
up or down depending on prevailing market conditions, as the greatest expense of
production is the labour required to manufacture the composite bodywork.
Page | 20
5.0 Materials, Manufacture and Cost
5.1 COMPOSITE_PARTS:
5.1.1 COMPOSITE_COSTING_METHODOLOGY
The primary method of manufacture for the bodywork sections is Vacuum
Infusion Processing. These parts use a common specification and pricing model, the
basis of which is explained below:
The costing of the GFPR and CFRP parts has been reduced into three
components:
 The price of the materials used, calculated based on the volume of the
part.
 The hourly costs of manufacture such as price of labour and factory
overhead rates, based on the time taken to lay up the parts.
 The tooling costs, which have been derived using an online calculator
from mouldbox.com, as well as through consultation with a professional
toolmaker from Fibreglass Solutions Ltd.
Material Costs: Resin

Knowing the grade of polymer and glass mat to be used, as well as the ratio by
weight of the two, it is possible to calculate a final part density. This, in conjunction with
the volume of the part, gives a weight of resin per part, and therefore the cost.
Where:
ρ_resin = Resin Density (g/mm3)
ρ_glass = Glass Density (g/mm3)
a = %age Resin by Weight
b = %age Glass by Weight
ρ_part = Part Density (g/mm3)
(ρ_resin*a) + (ρ_glass*b) = ρ_part
Therefore:
vol_part = Part Volume (mm3)
mass_part = Part Mass (g)
mass_resin = Resin Mass (g)
(ρ_part*vol_part) * a = mass_resin
rate_resin = Resin Price per Kilogram (£/Kg)
cost_resin = Cost of Resin in Part (£)
(mass_resin/1000) * rate_resin = cost_resin
This gives the material cost of the resin in a given part.
Material Cost: Glass

The glass is sold on rolls by the metre. With the width and length of the roll and
part known, an optimal cutting direction can be found, and the price per layer of glass
mat derived. This is then multiplied by the number of layers required to build the desired
part thickness, to give a material cost.
To find optimal part orientation, allowing for 10mm margin around each cut section:
l_part = Part Length (long) (mm)
w_part = Part Width (short) (mm)
Page | 21
Henry Wallace
w_roll = Glass Roll Width

sheets_l = no. lengths fit to roll width
sheets_w = no. widths fit to roll width
w_roll / (l_part+20) = sheets_l
w_roll / (w_part+20) = sheets_w
These results are rounded down, and then compared to the calculated figure, to
calculate the scrap generated. The scrap is then divided by the number of complete
sheets to generate a waste rate for comparison:
round_l = sheets_l rounded down
round_w = sheets_w rounded down
waste_l = waste lengthways
waste_w = waste widthways
(sheets_l - round l) / round_l = waste_l
(sheets_w – round_w) / round_w = waste_w
Whichever waste rate is lower, that orientation is taken forward. To find the price per
layer of glass, assuming the lengthways orientation was found to be more efficient:
w_part = Part Width (short) (mm)
round_l = sheets_l rounded down
rate_glass = glass matting price per metre (£/m)
cost_layer = cost per layer of glass (£)
(w_part / round_l) * (rate_glass / 1000) = cost_layer
The part glass cost is then given simply by multiplying the cost per layer by the number
of layers required. This pricing model for glass is comprehensive, requiring basic user
inputs and generating a robust price for glass based on actual cutting methods.
Hourly Costs:
The labour costs of GFRP are the greatest part costs, as laying up composites is
time consuming work. To model the cost of labour and other variable costs, a workrate
was derived from an instructional video on fibreglass layup, in which a layer of 500mm x
300mm was layed in 2 minutes. This gave a work rate by area of 7500 mm2/min. By
multiplying this with the thickness of the part in millimetres and dividing by the number
of layers of glass matting being used, a work rate by volume was found. This was
5357mm3/minute.
Therefore:
vol_part = part volume (from CAD model) (mm3)
work_vol = work rate by volume (mm3/min)
time_lay = time for layup (min)
vol_part / work_vol = time_lay
Also:
area_part = part surface area (from CAD model) (mm2)
work_area = work rate by area (mm2/min)
time_gel = time for gel coat laying (min)
area_part / work_area = time_gel
The tool setup time is a function of the time taken to set up a tool, divided by the
number of cycles required before maintenance such as rewaxing is required. This is
expressed as:
Page | 22
tool_set = tool setup time (mins)
tool_maint = no. of cycles before tool maintenance
time_set = tool setup time per part (mins)
tool_set / tool_maint = time_set
By gathering all these costs, a total labour cost per part can be found:
rate_labour = hourly wage of labourer (£/hour)
cost_labour = labour cost per part (£)
((time_lay + time_gel + time_set) / 60) * rate_labour = cost_labour
Of course, labour costs are not the only variable costs associated with part
production, and the other factory overheads are far more variable from facility to
facility. This data is difficult to find, but one method from accounting is to provide this as
a ratio to the cost of labour. The generic ratio of overhead costs being 1.5 times the
labour cost has been used as a benchmark within the pricing model spreadsheet that
has been developed. This is a variable which would certainly change the actual price of
the components going to manufacture.
Tooling Costs:
The tooling costs within the pricing spreadsheet model have been generated by
mouldbox.com and are, despite their precision, merely an indication of cost. However,
rough prices of £1500-3500 per large tool, depending on complexity were suggested by
a professional from Fibreglass Solutions Ltd., and seem reasonable. The screenshots
from the mouldbox quotation website are available at each of the parts’ individual
entries, as well as in appendix. The tooling costs have also been split per part within the
pricing model relative to the duration of the tool for easy communication of part price.
List of Assumptions:
1. Gel coat material is priced as part of the whole resin material volume.
2. Factory overhead rate at 1.5 times the labour cost.
3. No change in layup speed due to complexity of part.
4. Catalyst prices assumed negligible.
5. Tooling lasts for a minimum 500 pulls.
6. Carbon finish panels have 2 layers of carbon matting – one for each side.
Page | 23
Henry Wallace
5.1.2 FIBREGLASS_PARTS_SPECIFICATION
Material Specification:
Deltech P502 Polyester (Datasheet in Appendix 3.)
Aerialite S-Glass Mat – 200gsm (Datasheet in Appendix 3.)
Carbon Black Twaron 200g 2/2 Twill Decorative Carbon Weave
Material Selection Reason:
P502 is a good quality unsaturated polyester resin, suitable for use in marine
environments.
Aerialite is a brand of S-glass, which is a higher strength than standard E-glass. It is
primarily marketed as a material for surf board manufacture but is simply a high
strength woven glass mat for any application.
The carbon fibre used is slightly stronger than the glass, but is mainly decorative, and
isn’t being used on particularly structural parts.
Cost (See Section 5.3):
Resin: £1.50/Kg
Glass: £0.915/m
Carbon: £17/m
Process:
Vacuum Infusion Processing
Process Selection Reason:
These are low volume parts with complex curvature, which require high stiffness.
Vacuum Infusion Processing can utilise low cost soft epoxy tooling, while giving a good
quality finish on all surfaces. This near net process is appropriate for all bodywork
sections.
Tooling:
The tooling being used is made from a master, constructed out of high density pattern-
making foam. Constructed from MDF and glass reinforced resin, these tools have a
lifetime of over 500 parts, but tool degradation beyond 500 is likely, requiring more
tools for higher production quantities. A tooling quotation website, mouldbox.com has
been used to provide estimates for tooling production cost.
Page | 24
ITEM 1.1.2 C_PANEL_BACK
For material selection and costs, see section
5.1.2
Variations:
This part has only 1 configuration, and no
mirrored counterpart.
Tooling:
This will be a complex mould, consisting of
multiple internal and external sections to
support the geometry. The internal sections
are merely for support during the complex
laying up process but are not subject to high
forces, as the vacuum bag deals with these internally.
Tooling cost: £2565.46 inc VAT (500 parts)
Inserts:
M6 threaded inserts required on base part.
Cost:
Per Part: £405.22
Assuming multiples of 500
units.
For full price breakdown, see
costing model in Appendix 1.
Page | 25
Henry Wallace
ITEM 1.3 C_PANEL_TOP

Variations:
For material selection and costs, see
section 5.1.2
Tooling:
This will be a simple mould, with no
collapsing cores. Line of draw indicated on
screenshot below.
Inserts:
3mm steel rod in rear slot feature required.
M6 Threaded inserts required for hinge connection feature on underside.
Cost:
Per Part: £318.16
Assuming multiples of
500 units.
For full price breakdown,
see costing model in
Appendix 1.
Page | 26
ITEM 1.4 C_PANEL_BOTTOM
For material selection and costs, see
section 5.1.2
Variations:
Tooling:
screenshot below.
Inserts:
None required.
Cost:
Per Part: £265.01
Assuming multiples of 500 units.
Page | 27
Henry Wallace
ITEM 2.7 O_LEFT_STRUT1 / 4.7 O_RIGHT_STRUT1

For material selection and costs, see section 5.1.2
Variations:
This part is to be made in a left and right configuration.
Tooling:
This will be a simple mould, with no collapsing cores. Auto generated line of draw
indicated on screenshot below.
Tooling cost: £1765.51 inc VAT (500
parts)
Inserts:
M6 Threaded Inserts x4, 2 fore, 2
aft for attaching to chassis.
Cost:
Per Part: £90.97
For full price
breakdown, see costing
model in Appendix 1.
Page | 28
Variations:
Tooling:
This will be a simple mould, with no collapsing cores. Line of draw indicated on
screenshot below.
parts)
Inserts:
M6 Threaded Inserts x4, 2 fore, 2 aft
for attaching to chassis.
Cost:
Per Part: £80.22
Page | 29
Henry Wallace

Variations:
Tooling:
screenshot below.
Inserts:
M6 Threaded Inserts x4, 2
fore, 2 aft for attaching to
chassis.
Cost:
Per Part: £99.18
Assuming multiples
of 500 units.
For full price
breakdown, see
costing model in
Appendix 1.
Page | 30
ITEM 2.10 O_LEFT_PANEL1 / 4.10 O_RIGHT_PANEL1
Variations:
Tooling:
screenshot below.
Inserts:
None, panel clipped with tongue and groove
feature (not shown).
Cost:
Per Part: £53.53
For full price
breakdown, see
costing model in
Appendix 1.
Page | 31
Henry Wallace

Variations:
Tooling:
screenshot below.
Inserts:
None, panel clipped with tongue and
groove feature (not shown).
Cost:
Per Part: £174.00
For full price
breakdown, see costing
model in Appendix 1.
Page | 32
Variations:
Tooling:
screenshot below.
parts)
Inserts:
Extras:
This part is to have aesthetic surface
layers of carbon fibre
mat. The additional
price of this is £16.05.
Cost:
Per Part: £178.66
Assuming multiples
of 500 units.
For full price
breakdown, see
costing model in
Appendix 1.
Page | 33
Henry Wallace

Variations:
Tooling:
collapsing cores. Line of draw
Tooling cost: £1058.98 inc VAT
(500 parts)
Inserts:
None, panel clipped with tongue
and groove feature (not shown).
Cost:
Per Part: £6.08
Assuming multiples
of 500 units.
For full price
breakdown, see
costing model in
Appendix 1.
Page | 34
Variations:
This part is to be made in a left and right
configuration.
Tooling:
This will be a complex mould, consisting
of multiple internal and external sections
to support the geometry. The internal
sections are merely for geometric
support during the complex laying up
process but are not subject to high
forces, as the vacuum bag deals with
these internally. Line of draw incorrect on
screenshot below.
Inserts:
M6 threaded inserts
x6, for attaching to
chassis elements.
Cost:
Per Part: £194.62
500 units.
For full price
breakdown, see
costing model in
Appendix 1.
Page | 35
Henry Wallace

Variations:
configuration.
Tooling:
screenshot below.
Inserts:
None, panel clipped with tongue and groove
feature (not shown).
Cost:
Per Part: £72.67
500 units.
For full price
breakdown, see
costing model in
Appendix 1.
Page | 36
ITEM 3 O_LEFT_WING / 5 O_RIGHT_WING
Variations:
This part is to be made in a left and
right configuration.
Tooling:
collapsing cores. Line of draw
parts)
Inserts:
Cost:
Per Part: £137.99
Assuming multiples
of 500 units.
For full price
breakdown, see
costing model in
Appendix 1.
Page | 37
Henry Wallace
ITEM 2.5 O_LEFT_PROP_SHROUD_BACK / 4.5

O_RIGHT_PROP_SHROUD_BACK
Variations:
configuration.
Tooling:
This will be a simple mould, with no collapsing
cores. Line of draw indicated on screenshot below.
Inserts:
None, panel clipped with tongue and groove feature
(not shown).
Extras:
This part is to have aesthetic surface layers of
carbon fibre mat. The additional price of this is
£5.86.
Cost:
Per Part: £59.66
500 units.
For full price
breakdown, see
costing model in
Appendix 1.
Page | 38
ITEM 2.6 O_LEFT_PROP_SHROUD_FRONT / 4.6
O_RIGHT_PROP_SHROUD_FRONT
Variations:
configuration.
Tooling:
screenshot below.
parts)
Inserts:
None, panel clipped with tongue and groove feature (not shown).
Extras:
This part is to have aesthetic surface layers of carbon fibre mat. The additional price of
this is £4.56.
Cost:
Per Part: £31.55
500 units.
For full price
breakdown, see
costing model in
Appendix 1.
Page | 39
Henry Wallace
5.2 GENERAL_PARTS:
ITEM 1.1.1 DOME
Perspex 000 Clear BS6262
Perspex has exceptional optical
properties, as well as adequate strength
in the 20mm thickness of the dome to
support the craft at pressure.
Material Costs (See Section 5.3):
Sheet - 20x2030x1523mm £776.92
incVAT
1 sheet will be adequate per dome.
Process:
Drape Forming, Drilling
The 20mm sheet will adequately bend
under its own weight on a single mould
once heated, and drape forming allows the
surface finish on the outer edge to remain
optimal. Low tooling costs are also
attractive. A secondary drilling operation
is required to create the clearance holes
for the clamping assemblies. This will be done once the dome is draped to prevent
changes in form of the mould. Finishing and chamfering of the edges is then also
required.
Tooling:
Single positive mould manufactured in MDF and resin. A cost for the tooling has been
generated using the mouldbox online quote generator, however this is a higher grade of
tooling than is really required, and as such the pricing is highly conservative. The
durability of the tool should be near indefinite, and more than enough for the 1000 units
being costed. Line of draw indicated on screenshot below.
Cost Calculations:
Material Cost:
£776.92 incVAT
Tooling Cost:
£7060.73 incVAT
Tooling Cost per Part:
£7.06
Labour:
Assuming 2.5 hours at £10/hour, with factory overhead rate of 1.5.
(2.5*10)*1.5 = £37.5
Price per Part:
Material Cost + Tooling Cost per Part + Labour
£776.92 + £7.06 + £22.5 = £821.48
Page | 40
Dome Tooling Quote:
Page | 41
Henry Wallace
ITEM 5.1.1.3 REAR_CHASSIS

SAE 316 N Stainless Steel
This is a marine grade stainless steel, with the N
denoting increased nitrogen content. This
increases its resistance to corrosion and pitting in
joins and folds. While costly, this alloy is the most
appropriate for repeated submersion in salt water.
20mm Round Bar £100.98/3m, £33.66/m
25mm Round Bar £131.16/3m, £43.72/m
2500x1250x10mm Plate £2,308.70, £738.8/m2
Process:
Bending over Former, Fabrication, Cutting, Drilling, Welding
This is a complex part with formed curved geometry and welded chassis structure. It is
unsuitable for casting or other near net shape processes and must be fabricated.
Tooling:
This part will require several fixtures and jigs to aid the operator in joining the chassis
together. Of note is the former for the ring section. An allowance of £4000 has been
given for the fabrication of the appropriate equipment, which is generous.
Costing Calculations:
Material Costs:
20mm Bar 240mm Length x 6
20mm Bar 130mm Length x 10
20mm Bar 600mm Length x2
Total 20mm Bar = 3940mm, 3.94m
25mm Bar 640mm Length x2
Total 25mm Bar = 1280mm, 1.28m
10mm Plate 160 x 40mm x2
Total 10mm Plate = 108000mm2, 0.108m2
Total Material Costs: (3.94*33.66) + (1.28*43.72) + (0.108*738.8) = £268.37
Tooling Costs:
£4000
£4
Labour:
Assuming 6 hours at £20/hour, with factory overhead rate of 1.5.
(6*20)*1.5 = £180
Price per Part:
Material Cost + Tooling cost Per Part + Labour
£268.37 + £4 + £180 = £452.37
Page | 42
ITEM 1.1.4 DOME_SEAL_BACK
Neoprene BS2752 C50
This is a rubber which is highly resistant to
degradation due to sunlight or seawater
exposure, as well as being tough, and an
appropriate hardness for clamping acrylic
without causing damage.
4mm Thick Roll, 1m wide £113.70/m
Process:
Cutting, Drilling
This part needs to be cut to shape, and then drilled. The shaping happens during the
clamping assembly operation.
Tooling:
This part requires minimal tooling. Assume £500 for cutting and inspection guides.
Material Costs:
Neoprene Roll, strips 1.4m x 100mm. Assume 9 strips from 1m wide roll.
(Price per metre * 1.4m) / 9 strips
(113.70 * 1.4) / 9 = £17.70
Tooling Costs:
£500
£0.50
Labour:
(0.5*10)*1.5 = £7.50
Price per Part:
£17.70 + £0.50 + £7.50 = £25.70
Page | 43
Henry Wallace
ITEM 1.1.5 TOP_CLAMP

This is a marine grade stainless steel, with the
N denoting increased nitrogen content. This
increases its resistance to corrosion and pitting
in joins and folds. While costly, this alloy is the
most appropriate for repeated submersion in
salt water.
2500x1250x10mm Plate £2,308.70, £738.8/m2
Process:
Bending over Former, Cutting, Drilling
This is a complex part with formed curved geometry. It is suitable for forming from plate.
Tooling:
This part will require a bending former and inspection jigs. Assume £700 for fabrication
of these.
Material Costs:
10mm Plate 1500 x 100mm = 150000mm2, 0.15m2
0.15 * 738.80 = £110.82
Tooling Costs:
£700
£0.7
Labour:
(0.5*10)*1.5 = £7.50
Price per Part:
£110.82 + £0.70 + £7.50 = £119.02
Page | 44
ITEM 1.1.9.2 C_PAD
BASF Terluran GP-22 ABS
Terluran GP-22 is a versatile ABS grade which will suit
this part well.
Generic ABS Price £800/ton
Process:
Injection Moulding
This is a thin walled polymer part suitable for
manufacture by injection moulding.
Tooling:
Because of the low volume of production, soft tooling can be used which has a low
durability but will give an adequate finish. An estimate from emould.net has been used
which specifies tooling suitable for sub 5000 cycles. As the tool will be 4 cavity, and
only 2000 units are initially desired, this will be adequate and cost effective.
Machine Selection:
Milakron K-TEC 60s 111 w/ Mid Size Barrel (Datasheet in appendix 4.)
Machine Selection Reason:
The K-TEC 60s is good quality, appropriately small machine which can fit a low volume
barrel which will be capable of moulding this low volume of small parts on soft tooling.
The emould.net gives a price per component for manufacture in china of $0.16 US per
unit. The price for manufacture in the UK has been calculated and the figure shown
below.
Price per Part £0.72
For full detail, see costing spreadsheet screenshot.
Datasheets in appendix
Page | 45
Henry Wallace
Page | 46
Confidence of Fill: 100%, no issues filling foreseen.
Fill Time: 3.5s
Cooling Time: The part will be robust enough to eject after 42s, this is slow, but due to
the desired part thickness and low volume, this is acceptable.
Page | 47
Henry Wallace
Tooling:
This requires a simple two part mould. Because of the low volume of production, soft
tooling can be used which has a low durability but will give an adequate finish. An
estimate from emould.net has been used which specifies tooling suitable for sub 5000
cycles. As the tool will be 4 cavity, and only 2000 units are initially desired, this will be
adequate and cost effective.
Page | 48
ITEM 1.1.9.4 C_MOUNT
This is a marine grade stainless steel,
with the N denoting increased nitrogen
content. This increases its resistance
to corrosion and pitting in joins and
folds. While costly, this alloy is the
most appropriate for repeated
submersion in salt water.
2500x1250x10mm Plate £2,308.70, £738.8/m2
30mm Tube £55.72//6m, £9.27/m
Process:
Bending over Former, Cutting, Drilling, Welding
This is a complex part with formed curved geometry. It is suitable for forming from plate,
the bar section is bent and joined by welding.
Tooling:
This part will require two bending formers and inspection jigs. Assume £1200 for
fabrication of these.
Material Costs:
10mm Plate 800 x 60mm = 48000mm2, 0.05m2
30mm Tube 480mm, 0.48m
(0.05 * 738.80) + (0.48*9.27) = £41.39
Tooling Costs:
£1200
£1.20
Labour:
Assuming 1 hour at £10/hour, with factory overhead rate of 1.5.
(1*10)*1.5 = £15
Price per Part:
£41.39 + £1.20 + £15 = £57.59
Page | 49
Henry Wallace
ITEM 1.1.9.5 C_ARM

Terluran GP-22 is a versatile ABS grade
which will suit this part well.
Generic ABS Price £800/ton
Process:
Injection Moulding
This is a thin walled polymer part suitable for manufacture by injection moulding. It also
contains a small rare earth magnet in the thick end, which will be moulded around.
Machine Selection:
Milakron K-TEC 60s 111 w/ Small Sized Barrel (Datasheet in appendix 4.)
Machine Selection Reason:
The K-TEC 60s is good quality, appropriately small machine which can fit a low volume
barrel which will be capable of moulding this low volume of small parts on soft tooling.
Calculations & Cost:
The emould.net gives a price per component for manufacture in china of $0.15 US per
unit. The price for manufacture in the UK has been calculated and the figure shown
below.
Price per Part £0.78
For full detail, see costing spreadsheet screenshot overleaf.
Datasheets in appendix
Page | 50
Page | 51
Henry Wallace
Confidence of Fill: 100%, no issues filling foreseen.
Fill Time: 2.7s
Cooling Time: The part will be robust enough to eject after 40s, this is slow, but due to
the desired part thickness, low volume, and the over moulding onto a magnet, this is
acceptable.
Page | 52
Tooling:
This requires a simple two part mould. Because of the low volume of production, soft
tooling can be used which has a low durability but will give an adequate finish. An
estimate from emould.net has been used which specifies tooling suitable for sub 5000
cycles. As the tool will be 4 cavity, and only 2000 units are initially desired, this will be
adequate and cost effective.
Page | 53
Henry Wallace
ITEM 1.1.10 DOME_SHIELD_F_I / 1.1.11 DOME_SHIELD_F_O

Variations:
This part is to be made in an internal and
external variant, which are concentric to
each other and practically identical. Costs
have been calculated for the slightly larger of
the two.
Neoprene BS2752 C50
This is a rubber which is highly resistant to degradation due to sunlight or seawater
exposure, as well as being tough, and an appropriate hardness for clamping acrylic
without causing damage.
4mm Thick Roll, 1m wide £113.70/m
Process:
Cutting, Drilling
This part needs to be cut to shape, and then drilled. The shaping happens during the
clamping assembly operation.
Tooling:
This part requires minimal tooling. Assume £500 for cutting and inspection guides.
Material Costs:
Neoprene Roll, strips 0.9m x 50mm. Assume 1 strips from 1m wide roll.
(Price per metre * 0.05) / 1 strips
(113.70 * 0.05) / 1 = £5.69
Tooling Costs:
£500
£0.50
Labour:
(0.5*10)*1.5 = £7.50
Price per Part:
£5.69 + £0.50 + £7.50 = £13.69
Page | 54
ITEM 1.1.12 FRONT_CLAMP / 1.1.13 FRONT_BAR
This is a marine grade stainless
steel, with the N denoting
increased nitrogen content. This
increases its resistance to
corrosion and pitting in joins and
folds. While costly, this alloy is the
most appropriate for repeated
submersion in salt water.
2500x1250x10mm Plate £2,308.70, £738.8/m2
20mm Round Bar £100.98/3m, £33.66/m
Process:
Bending over Former, Cutting, Drilling, Welding
This is a complex part with formed curved geometry. It is suitable for forming from plate,
the bar sections are joined by welding.
Tooling:
This part will require bending formers and welding and inspection jigs. Assume £1000
for fabrication of these.
Material Costs:
10mm Plate 900 x 60mm = 54000mm2, 0.06m2
20mm Bar 250mm, 0.25m
(0.06 * 738.80) + (0.25*33.66) = £78.24
Tooling Costs:
£1000
£1.00
Labour:
Assuming 1 hour at £10/hour, with factory overhead rate of 1.5.
(1*10)*1.5 = £15
Price per Part:
£78.24 + £1.00 + £15 = £94.24
Page | 55
Henry Wallace
ITEM 1.2 BOOT_HINGE

This is a marine grade stainless steel, with the
N denoting increased nitrogen content. This
increases its resistance to corrosion and pitting
in joins and folds. While costly, this alloy is the
most appropriate for repeated submersion in
salt water.
30mm Tube £55.72//6m, £9.27/m
10mm Tube £65.36/5m, £13.07/m
Process:
Cutting, Welding
This is a simple part, wanted in small quantities from a relatively unusual grade of steel.
Tooling:
This part will require minimal jigs. Assume £100 for the fabrication of these.
Material Costs:
(0.03 * 9.27) + (0.17*13.07) = £2.50
Tooling Costs:
£100
£0.10
Labour:
Assuming 0.25 hour at £10/hour, with factory overhead rate of 1.5.
(0.25*10)*1.5 = £3.75
Price per Part:
£2.50 + £0.10 + £3.75 = £6.35
Page | 56
ITEM 2.1 O_LEFT_CHASSIS_ELEMENTS / 4.1 O_RIGHT_CHASSIS_ELEMENTS
Variants:
This part is a collection of two not fully specified structural elements, which are to be
fabricated. They consist of the front and rear chassis rings, which bolt to the bodywork
struts and panelling on the outriggers. The costing of these parts is done in slightly
looser terms, as these sections require further optimisation and testing. These will be
required in both left and right variants.
This is a marine grade stainless steel,
with the N denoting increased nitrogen
content. This increases its resistance to
corrosion and pitting in joins and folds.
While costly, this alloy is the most
appropriate for repeated submersion in
salt water.
2500x1250x10mm Plate £2,308.70,
£738.8/m2
Process:
Fabrication, Cutting, Welding, Bending around Former, Drilling
These are some relatively complex parts, wanted in small quantities from a relatively
unusual grade of steel. Fabrication allows their manufacture in a relatively financially
acceptable manner.
Tooling:
These elements will require some jigs and formers. Assume £2500 for the fabrication of
these.
Material Costs:
10mm Plate 1200 x 70mm = 84000mm2, 0.084m2
10mm Plate 1000 x 100mm = 100000mm2, 0.1m2
10mm Plate 300 x 130mm = 39000mm2, 0.039m2
10mm Plate 80 x 60mm x2 = 4800mm2, 0.005m2 x2
(0.84+1+0.39+0.05+0.05) * 738.8 = £172.14
Tooling Costs:
£2500
£2.50
Labour:
Assuming 4 hours at £10/hour, with factory overhead rate of 1.5.
(4*10)*1.5 = £60
Price per Part:
£172.14 + £2.50 + £60 = £234.64
Page | 57
Henry Wallace

Variations:
This part is to be made in a left and
right configuration.
Perspex has exceptional optical
properties, 10mm thickness is plenty
to provide shielding for the user from
the thruster units.
Sheet - 10x2030x1523mm £311.39 incVAT,
1 sheet will fit 24 panels – overall part dimensions 680 x 150mm
Process:
Drape Forming
The sheet will adequately bend under its own weight on a single mould once heated, and
drape forming allows the surface finish on the outer edge to remain optimal. Low tooling
costs are also attractive.
Tooling:
Single positive mould manufactured in MDF and resin. A cost for the tooling has been
generated using the mouldbox online quote generator, however this is a higher grade of
tooling than is really required, and as such the pricing is highly conservative. The
durability of the tool should be near indefinite, and more than enough for the 1000 units
being costed. Line of draw indicated on screenshot below.
Cost Calculations:
Material Cost:
311.39 / 24 = £12.97
Tooling Cost:
£1213.62 incVAT
£1.21
Labour:
(0.5*10)*1.5 = £7.50
Price per Part:
Material Cost + Tooling Cost per Part + Labour
£12.97 + £1.21 + £7.50 = £21.68
Page | 58
Left Panel Tooling Quote:
Page | 59
Henry Wallace
5.3 List of Material Suppliers and Quotations

5.3.1 Polyester Resin
Grade Used: Deltek P502 Unsaturated Polyester Resin
Supplier: Deltech Europe
Price £1.5/Kg
Datasheet in Appendix 3.
5.3.2 Woven Fibreglass Mat

Grade Used: S Glass 200gsm Plain Weave Aerialite
Supplier: East Coast Fibreglass Supplies
Manufacturer: BGF Industries
Price: £915/100m, £0.915/m
Link: https://www.ecfibreglasssupplies.co.uk/product/s-glass-200gsm-6oz-plain-
weave-30-aerialite
5.3.3 Woven Carbon Fibre Mat

Grade Used: Carbon Black Twaron 200g 2/2 Twill Decorative Carbon Weave
Supplier: EasyComposites.co.uk
Price: 1m wide roll £17/m
Link: http://www.easycomposites.co.uk/#!/fabric-and-reinforcement/carbon-fibre-
reinforcement/hybrid-and-decorative-carbon-fabrics/carbon-black-twaron-hybrid-
1m.html
5.3.4 Stainless Steel Tube and Bar Stock

Grade Used: SAE 316 N Marine Grade
Supplier: Metals 4U
Prices:
10mm Tube £65.36/5m, £13.07/m
20mm Round Bar £100.98/3m, £33.66/m
25mm Round Bar £131.16/3m, £43.72/m
30mm Tube £55.72//6m, £9.27/m
Link: https://www.metals4u.co.uk/stainless-steel/c8
5.3.5 Stainless Steel Plate

Grade Used: SAE 316 N Marine Grade
Supplier: Lakeland Steel
Price: 2500x1250x10mm Plate £2,308.70, £738.8/m2
Link: http://lakelandsteel.uk/metal-sheet-steel-sheet/stainless-steel/stainless-steel-
sheet/10mm-316-stainless-steel-2b-sheet-plate-profiles-blanks-custom-cut-to-size-
free-of-charge-enter-exact-dimension-for-pricing/
Page | 60
5.3.6 Acrylic
Grade Used: Perspex 000 Clear BS6262
Supplier: theplasticshop.co.uk
Price:
Sheet - 10x2030x1523mm £311.39 incVAT,
Sheet - 20x2030x1523mm £776.92 inc VAT
Link: https://www.theplasticshop.co.uk/clear-perspex-sheet-3mm-4mm-5mm-6mm-
8mm-10mm-12mm-15mm-20mm-25mm-thick.html
5.3.7 Neoprene
Grade Used: Neoprene BS2752 C50
Supplier: Maclellan Rubber
Price: 4mm Thick Roll, 1m wide £113.70/m (monomer.com)
Link: https://maclellanrubber.com/product/0693-bs2752-c50-50-shore-specification-
neoprene-chloroprene-cr-rubber-sheet
5.3.8 ABS
Grade Used: BASF Terluran GP-22 ABS
Supplier: INEOS Styrolution Group
Price: £800/ton (Generic ABS)
5.3.9 Composites Tooling

Supplier: Mouldbox
Grade: Mouldbox gives a quotation for composites tooling, suitable for 500 pulls for a
GFRP part. The mould construction techniques are similar to those used for other soft
tooling such as for drape forming. Drape forming tools, however, experience less wear
and tend to cost less. As such, where used as an estimate for non GFRP processes, the
durability is estimated at around 5000 pulls.
A separate consultation with a professional from Fibreglass Solutions Ltd. confirmed the
general accuracy of the mouldbox quotations with an example of tooling for a 1m x 1m
thin panel, durable to 500 pulls costing £2000 with 4 cavities on the tool.
Link: https://www.mouldbox.com/
5.3.10 Injection Moulding Tooling

Supplier: emould.net
Grade: Within the emould calculator, the mold life has been generally been specified to
sub 5000 cycles. This tooling is particularly suited to making low precision parts in
small volumes. The prices of the relevant components (Item 1.1.9.2 C_PAD and Item
1.1.9.5 C_ARM) are significantly higher than would be desirable for larger scale
manufacture, but both being sub £1, are not a large concern.
Link: http://www.emold.net/view/Calculate.jsp
Page | 61
Henry Wallace
6.0 Bought-In Components

6.1 SCREWS, WASHERS & NUTS
Component Specification:
Screws: Metric Socket Button Screws A4 (316) grade Stainless Steel
Washers: TPR Rubber Metric Flat Washers
Nuts: Metric Hexagon Nyloc Nuts A4 (316) grade Stainless Steel
Sizes & Prices:
Screws
Nom. Size Length /mm Quantity Price Total
M8 50 12 £0.63 £7.56
40 12 £0.51 £6.12
M6 25 6 £0.18 £1.08
20 2 £0.16 £0.32
12 4 £0.12 £0.48
10 4 £0.13 £0.52
M3 12 24 £0.05 £1.20
6 2 £0.04 £0.08
Washers
Outer Diam
Nom. Size /mm Quantity Price Total
M8 18 24 £0.34 £8.16
M6 14 16 £0.25 £4.00
M3 9 2 £0.22 £0.44
Nuts
Nom. Size Quantity Price Total
M8 24 £0.16 £3.84
M6 16 £0.08 £1.28
Total £35.08
Supplier: Accugroup
Link: https://www.accu.co.uk/en/62-socket-button-
screws#elasticsearch_id_feature_681049=681049_701&elasticsearch_id_feature_6810
67=681067_161&id_elasticsearch_category=62&orderby=ranking&orderway=asc
Page | 62
6.2 OTHER COMPONENTS
ITEM 1.12 TL1000H
Component Specification: Toggle Latch 304
Stainless
Cost: £3
Supplier: Specialty Fasteners
Link: http://www.specialityfasteners.co.uk/tl-1000-
h.pdf
Reason for Selection: Reasonably priced fastener.
ITEM 1.1.9.3 C_CONSOLE & ITEM 1.1.9.10 C_PIN

Component Specification: Dive Computer
Console with mount for magnetic trigger, Custom
made by contractor.
Cost: £600 (estimated)
Supplier: Tritech
Link: http://www.tritech.co.uk/support-datasheet-
category/control-units
Reason for Selection: Tritech are an underwater
technology company producing components and control systems for underwater
vehicles. A control system is to be commissioned from them based on the P-Sea range
of dive computers.
ITEM 1.9 D_RING & 1.10 D_RING_BRACKET

Component Specification: 6 x 30mm A4-AISI 316 Marine
Grade Stainless Steel D Ring
Break Load: 700Kg
Cost: £0.80 Ring, £1 Plate
Supplier: GS Products
Link: http://www.gsproducts.co.uk/stainless-steel-d-rings/
Reason for Selection: These stainless steel D-rings are
appropriate to lift the Reefstormer in pairs. They are
corrosion resistant and well suited to lifting use in a marine environment.
Page | 63
Henry Wallace
ITEM 2.2 O_LEFT_BALLAST_BAG / ITEM 4.2

O_RIGHT_BALLAST_BAG
Component Specification: Underwater Duffle Bag
Cost: £8.17
Supplier: Xiamen Minghui (alibaba)
Link: https://www.alibaba.com/product-
detail/Custom-Waterproof-Duffle-Bag-PVC-
Duffle_60759868586.html?spm=a2700.7735675.2017115.15.HXDLem&s=p
Reason for Selection: This is a reasonably sturdy looking underwater duffle. It does
not need to be waterproof, as it is for holding coated lead weight.
ITEM 2.23 HEADLIGHTS / 4.23 HEADLIGHTS

Component Specification: 1500 Lumen Subsea LED
Light 300m depth rating
Cost: £73.49, £146.98 per pair
Supplier: Blue Robotics
Link:
https://www.bluerobotics.com/store/electronics/lumen-light-r1/
Reason for Selection: Reasonable AUV headlights.
ITEM 2.3 O_LEFT_BUOYANCY_BAG /

O_RIGHT_BUOYANCY_BAG
Component Specification: EP-50 Lift Bag, Made -to-
order
Cost: £40 (estimate from comparable bags)
Supplier: Headway Tech
Link: http://www.headway-tech.com/ht_products/air-
filled-buoyancy-bags/enclosed-pillow-air-lift-bags/
Reason for Selection: These lift bags are available for
make-to-measure, and designed for buoyancy control with appropriate relief valves
built in.
ITEM 2.4 COPENHAGEN_SUBSEA_VM

Component Specification: Copenhagen Subsea VM Compact Rim
Driven Thruster for Underwater Use
Attachment: Proprietary Mounting Lug 4x M8 Bolts, Subconn
Circular 16
Cost: £500 (estimate from comparable drive systems)
Supplier: Copenhagen Subsea
Link: https://www.copenhagensubsea.com/vm
Reason for Selection: The Copenhagen subsea thrusters are the
only rim-driven underwater thrusters on the market. The hubless
design is aesthetically desirable, less prone to tangling, more efficient,
Page | 64
and quieter than traditional thrusters with a central drive chain. This drawback comes at
a cost, but it is an acceptable cost.
Datasheet / manual in Appendix 5.
ITEM 6.1 CABLE_TIDY

Component Specification: Velcro Webbing Strap
Cost: £1.91
Supplier: Evaq8
Link: http://evaq8.co.uk/VELCRO-STRAP-For-Attachment-to-
Arm-Wrist-or-
Equipment.html?gclid=Cj0KCQjwuYTYBRDsARIsAJnrUXDCr41eShf8SlP26iiEmVpK48v
sk5D_ZjJNrftAKlvxlGphKOnESsEaAnRGEALw_wcB
Reason for Selection: A strap suitable for marine use.
ITEM 6.2 SUBCONN_16_C

Component Specification: MacArtney
Subconn 16 pin circular connector
Cost: £20
Supplier: MacArtney
Link: https://www.macartney.com/what-
we-offer/systems-and-
products/connectors/subconn/subconn-
circular-series/subconn-circular-12-16-
and-25-contacts/
Reason for Selection: This is the
connector which is compatible with the Copenhagen Subsea thruster, it is a robust,
waterproof connector which can transmit the appropriate power and data to drive and
control the thruster.
ITEM 6.3 FNC12220 ENC

Component Specification: FNC12220 Sealed Lead
Acid Battery 12V 22AH
Cost: £39.95
Supplier: Tayna Ltd
Link: https://www.tayna.co.uk/industrial-
batteries/numax/fnc12220/
Reason for Selection: This battery will run the
submarine for up to 3 hours. Lead acid is appropriate due
to its good performance in atmospherically sealed conditions and high stability
compared to LiPol.
Page | 65
Henry Wallace
ITEM 6.4 FABER H7 HP80

Component Specification: Faber H7 Steel HP80 Dive Cylinder
Material: High Pressure Steel
Finish: Hot Dip Galvanised
True Air Capacity: 80.1 ft3
Diameter: 7.25 inch
Height: 20.8 inch
Weight Empty: 28.3 lbs
Buoyancy Full / Empty: -8.1 / -1.7 lbs
Attachment: Thermo Pro DIN/K Standalone Valve with Yoke
Insert
Cost: £199.69 inclusive of valve
Supplier: Dive Gear Express LLC
Link: https://www.divegearexpress.com/high-pressure-steel-
cylinders-hot-dip-galvanized-4366
Reason for Selection: A high pressure steel tank which allows maximum air storage
with minimal volume. Weight not an issue within product, therefore the durability of a
steel tank was desired. Other air tanks may be used by end users.
ITEM 6.5 MILFLEX2 HOSE

Component Specification: Milflex Regulator Hose
Cost: £26.00
Supplier: Simply Scuba
Link: https://www.simplyscuba.com/products/miflex-
xtreme-regulator-hose-38-unf-
62cm?gclid=Cj0KCQjwlv_XBRDrARIsAH-
iRJTOzZPhj_iLavsp8u56uu5m6KtHGqzLZ0NihvBgCk9TGZweLuz0ircaAhUMEALw_wc
B&variant=43423434236
Reason for Selection: A rugged regulator hose, widely used in dive shops.
ITEM 6.6 RS 916-0940

Component Specification: CVPU Non Return Valve
10mm -1 to 15 bar
Cost: £11.22
Supplier: RS Components
Link: https://uk.rs-online.com/web/p/pneumatic-positive-
pressure-vacuum-non-return-valve-function-
fittings/9160940/
Reason for Selection: An appropriate non-return valve for the end of the air supply,
at reasonable price.
Page | 66
ITEM 6.8 BK3_CAMBAND
Component Specification: Supercam Camband
Cost: £14.14
Supplier: AP Diving
Link: https://www.apdiving.com/shop/bk3-super-
camband.html?gclid=CjwKCAjw_tTXBRBsEiwArqXyMn9sgzfnZpHTMH9kQs2CYytLL1iLf
QG5lXYVN-vghJzbWKFDmgdMLBoCXX4QAvD_BwE
Reason for Selection: Standard Camband
ITEM 6.9 CABLE

Component Specification: Cable
Cost: £0.70/m, 2m £1.40
Supplier: TLC Direct
Link: https://www.tlc-
direct.co.uk/Products/CA2dot5Gslash25.html?source=adwords&ad_position=1o1&ad_i
d=45425533757&placement=&kw=&network=g&matchtype=&ad_type=pla&product_i
d=CA2.5G%2f25&product_partition_id=174053346307&test=finalurl_v2&gclid=Cj0K
CQjwuYTYBRDsARIsAJnrUXA2cdZKrerq8vP5TR6Q12Zb2fe3V6qv3cEAdBcq-
B31poAJVavC92QaAhHMEALw_wcB
Reason for Selection: Cable
ITEM 6.10 SCUBAPRO_MK25_EVO

Component Specification: Scubapro MK25 EVO First
Stage Regulator
Attachment: Yoke Valve
Cost: £238
Supplier: Deep Blue Dive
Link: http://www.deepbluedive.com/scubapro-mk25-first-
stage.html?gclid=CjwKCAjw_tTXBRBsEiwArqXyMq25z1ttrkBr3oNun6jpD_wQfYmhsvJ_
7s07QJZXjwjqRXItKjHqaxoC-5gQAvD_BwE
Reason for Selection: The Scubapro MK25 Evo is an excellent first stage regulator,
which is available with Yoke or DIN valve connectors, allowing the end service providers
to use local tanks and hosing to streamline their operation.
Page | 67
Henry Wallace
ITEM 6.11 AN-05F AN

Component Specification: AN-05F AN Series
Diecast Aluminium NEMA Enclosure
Cost: $18.47
Supplier: Polycase
Link: https://www.polycase.com/an-05f
Reason for Selection: Reasonable Price
ITEM 6.13 JUP-20/80

Component Specification: Ingenia Jupiter
Digital Servo Drive JUP-20/80
Cost: £40 (estimate)
Supplier: Ingenia
Link: http://ingeniamc.com/products/jupiter-
digital-servo-drive
Reason for Selection: This servo drive is part of
a verified set up from Copenhagen Subsea,
guaranteeing that the thrusters used are compatible with this model.
ITEM 9 G1500M
Component Specification: G1500m Galvion Element
Anode
Cost: £15.50
Supplier: Anode Outlet
Link: https://www.anodeoutlet.co.uk/product/g1500m-
galvion-element-anode/
Reason for Selection: Reasonable quality pencil anode
system.
Page | 68
7.0 Assembly
The Reefstormer is assembled in three main subsections: The Central Section,
and each of the Outriggers. These assemblies are centred around the chassis and
structural elements of the submersible, with subassemblies below them for the
integration of the various components.
7.1 Central Structural Assembly
This is the base assembly for the whole BOB. There are two main operations: the
clamping of the front and rear sections. This will require 2 operators, with a time of 1
hour for each clamp assembly, including setup and tensioning.
Labour Required: 4 Hours
7.2 Central Assembly

The attachment of the bodywork and fixing parts to the rear of the vehicle. Time
allowed for this operation is 1 hour for two operators.
Page | 69
Henry Wallace
7.3 Outrigger Structural Assembly

This assembly is the base structure for the outrigger. Required for both left and
right outrigger assemblies. The time allowed for this assembly step is 1 hour for two
operators.
7.4 Outrigger Full Assembly

This operation sees the non-structural components being added to the outrigger,
making it ready for final assembly. 2 hours, 2 operators.
Page | 70
7.5 Reefstormer General Assembly
The attachment of the outriggers and wing bodywork sections to the central
section. The manipulation of the outriggers onto the main body will require appropriate
lifting equipment, but the process should be relatively quick. 1 hour, 2 operators.
7.6 Installation of Power and Air Systems

Some of the routing of power and air may occur upon delivery of the
Reefstormer, due to the localised regulation dive tanks and power supplies and the
necessity for training of operators in using the vehicle.
7.7 Assembly Costing
7.1 Central Structural Assembly x1
7.2 Central Assembly x1
7.3 Outrigger Structural Assembly x2
7.4 Outrigger Full Assembly x2
7.5 Reefstormer General Assembly x1
7.6 Installation of Power and Air Systems x1
Total Time: 18 Hours
Price: £10/Hour plus factory overhead of 1.5x
Total Cost: £27
Page | 71
Henry Wallace
8.0 Costings
8.1 Price Breakdown Per Unit
Costings below for run of 1000 units.
Composite Parts
Item
Part Name
No. Quantity Unit Cost Total Cost
1.1.2 C_PANEL_BACK 1 £405.22 £405.22
1.3 C_PANEL_TOP 1 £318.16 £318.16
1.4 C_PANEL_BOTTOM 1 £265.01 £265.01
2.7 /
O_LEFT_STRUT1 / O_RIGHT_STRUT1 2
4.7 £90.97 £181.94
2.8 / O_LEFT_STRUT2 /
2
4.8 O_RIGHT_STRUT2 £80.22 £160.44
O_LEFT_STRUT3 /
.9 / 4.9 2
O_RIGHT_STRUT3 £99.18 £198.36
2.1 /
O_LEFT_PANEL1 / O_RIGHT_PANEL1 2
4.10 £53.53 £107.07
2.11 / O_LEFT_PANEL2 /
2
4.11 O_RIGHT_PANEL2 £174.00 £348.00
2
4.14 O_RIGHT_PANEL3 £6.08 £12.15
2
4.15 O_RIGHT_PANEL6 £194.62 £389.24
2
4.16 O_RIGHT_PANEL7 £72.67 £145.33
3/5 O_LEFT_WING / O_RIGHT_WING 2 £137.99 £275.99
Carbon Finish Parts
2
4.12 O_RIGHT_PANEL3 £178.66 £357.33
2.5 / O_LEFT_PROP_SHROUD_BACK /
2
4.5 O_RIGHT_PROP_SHROUD_BACK £59.66 £119.32
2.6 / O_LEFT_PROP_SHROUD_FRONT /
2
4.6 O_RIGHT_PROP_SHROUD_FRONT £31.55 £63.09
Subtotal £3,346.62
Other Parts
1.1.1 DOME 1 £821.48 £821.48
1.1.3 REAR_CHASSIS 1 £452.37 £452.37
1.1.4 DOME_SEAL_BACK 1 £25.70 £25.70
1.1.5 TOP_CLAMP 1 £119.02 £119.02
1.1.9.2 C_PAD 2 £0.72 £1.44
1.1.9.4 C_MOUNT 1 £57.59 £57.59
1.1.9.5 C_ARM 2 £0.78 £1.56
1.1.10/1
DOME_SHIELD_F_I/O 2
1 £13.69 £27.38
Page | 72
1.1.12/1
FRONT CLAMP / BAR 1
3 £94.24 £94.24
1.2 BOOT_HINGE 2 £6.35 £12.70
2.1 / O_LEFT_CHASSIS_ELEMENTS /
2
4.1 O_RIGHT_CHASSIS_ELEMENTS £234.64 £469.28
2
4.13 O_RIGHT_PANEL4 £21.68 £43.36
Subtotal £2,126.12
Bought In Components
SCREWS WASHERS & NUTS 1 £35.08 £35.08
1.1.9.3/
C_CONSOLE / C_PIN 1 £600.00
1 £600.00
1.9/10 D_RING_BRACKET / D_RING 4 £1.80 £7.20
1.12 TL-1000-H 1 £0.00
2.2 / O_LEFT_BALLAST_BAG /
2
4.2 O_RIGHT_BALLAST_BAG £8.17 £16.34
2.3 / O_LEFT_BUOYANCY_BAG /
2
4.3 O_RIGHT_BUOYANCY_BAG £40.00 £80.00
2.4 /
COPENHAGEN_SUBSEA_VM 2
4.4 £500.00 £1,000.00
2.23 /
HEADLIGHTS 2
4.23 £146.96 £293.92
6.1 CABLE_TIDY 1 £1.91 £1.91
6.2 SUBCONN_16_C 2 £20.00 £40.00
6.3 FNC12220 ENC 1 £39.95 £39.95
6.4 FABER H7 HP80 1 £199.69 £199.69
6.5 MILFLEX2 HOSE 3 £26.00 £78.00
6.6 RS 916-0940 1 £11.22 £11.22
6.8 BK3_CAMBAND 1 £14.14 £14.14
6.9 CABLE 1 £1.40 £1.40
6.10 SCUBAPRO_MK25_EVO 1 £238.00 £238.00
6.11 AN-05F AN 1 £13.71 £13.71
6.13 JUP-20/80 1 £40.00 £40.00
6.14 LEAD BALLAST 1 £200.00 £200.00
9 G1500M 2 £15.50 £31.00
Subtotal £2,941.56
Assembly Cost £270.00
Total Cost per Unit £8,684.30
£8,684,30
Total Production Run Cost 0.00
Page | 73
Henry Wallace
8.2 Initial Investment and Break Even Analysis

Due to the low cost of tooling for the main sections of the craft, a basic list of
costings for the initial setup of manufacture has been conducted here, taking only
tooling into account.
Composite Parts
Version Tooling Total Tooling
Item No. Part Name s Cost Outlay
1.1.2 C_PANEL_BACK 1 £2,565.46 £2,565.46
1.3 C_PANEL_TOP 1 £2,376.61 £2,376.61
1.4 C_PANEL_BOTTOM 1 £1,776.97 £1,776.97
O_LEFT_STRUT1 /
2.7 / 4.7 2
O_RIGHT_STRUT1 £1,765.51 £3,531.02
O_LEFT_STRUT2 /
2.8 / 4.8 2
O_RIGHT_STRUT2 £1,321.85 £2,643.70
O_LEFT_STRUT3 /
2.9 / 4.9 2
O_RIGHT_STRUT3 £1,713.43 £3,426.86
O_LEFT_PANEL1 /
2.1 / 4.10 2
O_RIGHT_PANEL1 £1,160.96 £2,321.92
O_LEFT_PANEL2 /
2.11 / 4.11 2
O_RIGHT_PANEL2 £1,503.68 £3,007.36
2
4.14 O_RIGHT_PANEL3 £1,058.98 £2,117.96
2
4.15 O_RIGHT_PANEL6 £2,080.78 £4,161.56
2
4.16 O_RIGHT_PANEL7 £1,626.90 £3,253.80
O_LEFT_WING /
3/5 2
O_RIGHT_WING £2,424.76 £4,849.52
Carbon Finish Parts
2
4.12 O_RIGHT_PANEL3 £1,671.77 £3,343.54
O_LEFT_PROP_SHROUD_BACK
2.5 / 4.5 / 2
O_RIGHT_PROP_SHROUD_BAC
K £1,490.49 £2,980.98
O_LEFT_PROP_SHROUD_FRON
2.6 / 4.6 T/ 2
O_RIGHT_PROP_SHROUD_FRO
NT £1,245.58 £2,491.16
Subtotal £44,848.42
Other Parts
1.1.1 DOME 1 £7,060.73 £7,060.73
1.1.3 REAR_CHASSIS 1 £4,000.00 £4,000.00
1.1.4 DOME_SEAL_BACK 1 £500.00 £500.00
1.1.5 TOP_CLAMP 1 £700.00 £700.00
Page | 74
1.1.9.2 C_PAD 1 £757.92 £757.92
1.1.9.4 C_MOUNT 1 £1,200.00 £1,200.00
1.1.9.5 C_ARM 1 £895.26 £895.26
1.1.10/11 DOME_SHIELD_F_I/O 2 £500.00 £1,000.00
1.1.12/13 FRONT CLAMP / BAR 1 £1,000.00 £1,000.00
1.2 BOOT_HINGE 1 £100.00 £100.00
O_LEFT_CHASSIS_ELEMENTS
2.1 / 4.1 / 2
O_RIGHT_CHASSIS_ELEMENTS £2,500.00 £5,000.00
2
4.13 O_RIGHT_PANEL4 £1,213.62 £2,427.24
Subtotal £24,641.15
Total £69,489.57
Given the expected minimum sale price per vehicle of £20,000, a £10,000 profit
is assumed. As initial tooling outlay total for the entire manufacture (suitable for 500
pulls of composite parts) is £69,489.57, it is not unreasonable to assume that 10 units
would pay off initial expenses of manufacture including those of securing premises and
sale.
Page | 75
Henry Wallace
9.0 Specification Drawings

The following drawings are attached:
2xA1 General Assembly

2xA1 Central Structural Subassembly
1xA1 Rear Chassis
1xA1 Back Panel
1xA1 Propeller Shroud Front
1xA2 Clamp
Page | 76
Appendix 1: Composite Costing Model Spreadsheet
Using the calculations within 5.1.1 Composite Costing Methodology, this
spreadsheet was created to process the costing of composite parts. The user inputs are
held in a table which allows definition of material costs, as well as within the main table
which contains all the parts.
Page | 77
Henry Wallace
This section of the model shows the part inputs.
Page | 78
This section of the model shows determinisation of the most efficient cut orientation.
Page | 79
Henry Wallace
This section of the model shows how the resin and glass matting costs are determined.
Page | 80
This section of the model shows the labour costs, and the total costs.
Page | 81
Henry Wallace
Page | 82
Appendix 2: Injection Moulding Costing Model Spreadsheet
This spreadsheet was devised to provide an accurate cost and timescale for
injection moulding parts in the UK. The machine and material inputs have dedicated
sheets, and the part and tooling inputs are on each main sheet.
Page | 83
Henry Wallace
Page | 84
Appendix 3: Material Datasheets
The following material datasheets are attached:
Deltech P502 Polyester
Aerialite S-Glass Mat – 200gsm BGF Industries
Neoprene BS2752 C50
Page | 85
Henry Wallace
Page | 86
Appendix 4: Machine Datasheets
The following machine datasheets are attached:
Milakron K-TEC 60s 111
Page | 87
Henry Wallace
Page | 88
Appendix 5: Bought-In Component Datasheets
The following component datasheets are attached:
TL1000H Toggle Latch
Tritech P-Sea
Copenhagen Subsea VM Compact
Subconn 16 pin circular connector
Ingenia Jupiter Digital Servo Drive JUP-20/80
Page | 89

REEFSTORMER Technical Specification

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REEFSTORMER Technical Specification

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2018

Mr. Simon Harrison

ITEM 2.5 O_LEFT_PROP_SHROUD_BACK / 4.5 O_RIGHT_PROP_SHROUD_BACK

The Reefstormer improves on existing BOBs on the market in four ways:

The ascent and descent of the Reefstormer is controlled by buoyancy bags,

3.0 Parts Reference

Fastener part numbers not noted on reference.

1.1 1.3 1.2

1.4 1.9 1.10 1.12

Central Structural Assembly

1.1.3 1.1.2 1.1.5 1.1.1 1.1.9.4

1.1.4 1.1.1 1.1.9 1.1.12 1.1.11

2.2 2.14 2.13 2.10 2.6 2.7 2.3 2.5

2.23 2.15 2.16 2.1 2.8 2.9 2.12 2.4 2.11

3.2 Bill of Materials

OUTRIGGER_RIGHT_ STARBOARD SIDE

4.0 Production Quantities

Material Costs: Resin

Material Cost: Glass

w_roll = Glass Roll Width

ITEM 1.3 C_PANEL_TOP

ITEM 2.7 O_LEFT_STRUT1 / 4.7 O_RIGHT_STRUT1

ITEM 2.9 O_LEFT_STRUT3 / 4.9 O_RIGHT_STRUT3

ITEM 2.11 O_LEFT_PANEL2 / 4.11 O_RIGHT_PANEL2

ITEM 2.14 O_LEFT_PANEL5 / 4.14 O_RIGHT_PANEL5

ITEM 2.16 O_LEFT_PANEL7 / 4.16 O_RIGHT_PANEL7

ITEM 2.5 O_LEFT_PROP_SHROUD_BACK / 4.5

ITEM 5.1.1.3 REAR_CHASSIS

ITEM 1.1.5 TOP_CLAMP

Fill Time: 3.5s

ITEM 1.1.9.5 C_ARM

Confidence of Fill: 100%, no issues filling foreseen.

Fill Time: 2.7s

ITEM 1.1.10 DOME_SHIELD_F_I / 1.1.11 DOME_SHIELD_F_O

ITEM 1.2 BOOT_HINGE

ITEM 2.13 O_LEFT_PANEL4 / 4.13 O_RIGHT_PANEL4

5.3 List of Material Suppliers and Quotations

5.3.2 Woven Fibreglass Mat

5.3.3 Woven Carbon Fibre Mat

5.3.4 Stainless Steel Tube and Bar Stock

5.3.5 Stainless Steel Plate

5.3.9 Composites Tooling

5.3.10 Injection Moulding Tooling

6.0 Bought-In Components

ITEM 1.1.9.3 C_CONSOLE & ITEM 1.1.9.10 C_PIN

ITEM 1.9 D_RING & 1.10 D_RING_BRACKET

ITEM 2.2 O_LEFT_BALLAST_BAG / ITEM 4.2

ITEM 2.23 HEADLIGHTS / 4.23 HEADLIGHTS

ITEM 2.3 O_LEFT_BUOYANCY_BAG /

ITEM 2.4 COPENHAGEN_SUBSEA_VM

ITEM 6.1 CABLE_TIDY

ITEM 6.2 SUBCONN_16_C

ITEM 6.3 FNC12220 ENC

ITEM 6.4 FABER H7 HP80

ITEM 6.5 MILFLEX2 HOSE

ITEM 6.6 RS 916-0940

ITEM 6.9 CABLE

ITEM 6.10 SCUBAPRO_MK25_EVO

ITEM 6.11 AN-05F AN

ITEM 6.13 JUP-20/80

7.2 Central Assembly

7.3 Outrigger Structural Assembly

7.4 Outrigger Full Assembly

7.6 Installation of Power and Air Systems