Build Instruction: Frame

The support frame is required due to that pesky gravity we have on earth. To minimize the visual aspect of the frame, we used black components that are as small as possible. We want to the focus to be the ISS model.

The frame is constructed primarily from T-slot aluminum. This was selected due to relative low cost, simple construction, standard components (open-source friendly), and modularity. Note that you are free to create an alternative frame design with the materials of your choosing. The most important aspect is the interface to the ISS model. We’d love to have a variant that can hang from the ceiling. The components required are as listed in the Bill-of-Materials, here: https://github.com/ISS-Mimic/Mimic/wiki/Build-Instruction%3A-Bill-of-Materials#Frame

The overall frame layout is as pictured in the diagram (TBD Fig 1).

RECONCILE below steps with image file - I guess we need to insert images from power point and massage words to fit

Step 1: Safety first!! Gloves are required (leather or thick material)! Wear gloves until the frame is fully assembled, with caps in place covering all cut edges. The aluminum segments were cut to length at the factory. At these cut locations there will be sharp edges and perhaps barbs. Also, the clear polyethylene wrap collects some of the cut metal shavings. Keep this in mind when choosing where to unwrap the aluminum segments. Components will likely have small barbs and sharp edges on the ends where they were cut.

Step 2: Unwrap the aluminum segments (outside or above a trash can). See safety note above!!

Step 3: Base

• The base of the frame consists of a double-width backbone and multiple cross-pieces as pictured in TBD Fig 2.
• Assemble on a flat surface such as a table to ensure the pieces are flat when tightened down. -Aluminum extrusions are connected to each other using a combination of “L” brackets and spring nuts/screws. The spring nuts can be pushed into place by canting to one side, inserting, then pushing to align flat. It takes a little while to get used to inserting them, but it’s easier than trying slide them from the end! See insertion sequence shown in TBD Fig 3a-d.
• Apply rubber feet and caps as shown. These cover sharp edges.

Step 4: Vertical Supports

• Continue to wear gloves on this step as well. It is recommended that masking tape (or similar) be used to cover any exposed cut edges after the vertical segments are in place, if not immediately covered by the 3D-printed frame interface pieces.
• The vertical pieces attach with the same brackets and fasteners as used on the Base. The vertical segments at the ends of the backbone will have to be adjusted slightly once the 3D printed components are mounted to help squeeze them together just enough.
• Assemble as shown in Fig 4.

Step 5: Support Rods.

• Install Support Rod Bases (2020 stubs) on center Frame Supports. Secure with L-brackets. Drill/poke holes in Rubber Feet (smaller than rod diameter to provide friction with Suppor Rod for extra stability) and install on Support Rod Bases. Insert Support Rods through Rubber Feet and into Support Rod Bases. The Support Rod should drop down int groove of 2020 on the Frame Supports.

Detailed instruction image - update link with file when uploaded