Ive got a few interesting ideas, light weight and solid, I have not seen any one on the net go this way yet.
Vacuum formed poly carbonate sheets over foam for control surfaes.
it will be an interesting study!
http://www.plasticsmachining.com/magazine/199609/polycarbonate.html
Thermo Vacuum Forming Process:Formula for computing weight per square foot of polycarbonate sheet
Clamping
The clamp frame ensures the plastic sheet is held firmly in place during the vacuum forming process.
Heating
Radiant heaters are used to heat the sheet which has been positioned over the aperture of the vacuum forming machine. Thicker sheets may require both surfaces be be heated by moving heaters into position both above and below the sheet.
Pre-stretch
Is used to achieve "even" wall thickness. Air is introduced to blow a small "bubble" and the mold is then raised into the pre-stretched sheet.
Vacuum Forming
A vacuum is applied, the sheet is drawn into tight contact with the mold and the mold detail is picked up.
Plug Assist
Where a deep draw is required, a top "plug" may be used to push material into the mold during the vacuum forming process retaining even wall thickness.
Cooling and Release
The material is allowed to cool. The cooling process may be shortened with blown air and the molding is then released from the mold by introducing air pressure.
Finishing
After the part is vacuum formed, secondary services are performed, including: trimming, cutting, drilling, assembling, polishing, painting, and screening.
Lexan FR 60 SPECIFIC GRAVITY = 1.32
SPECIFIC GRAVITY multiplied by 5.2
multiplied by THICKNESS = LBS. PER SQUARE FOOT
ounce per (square yard) to pound per (square foot) (oz/yd² to lb/ft²): lb/ft² = 0.006944444444 × oz/yd²
.010 polycarbon sheet lb/sq ft=.06864
doped fabric Lb/sq ft=.082
sail fabric Lb/sq ft=.029
Dow high load 100 blue foam weighs 4 lbs for a 4x8 sheet.
yes we can build a very light and strong set of tail feathers.
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