Center Console Fabrication
The Problem
The connectors for pilot and copilot headphones protruded from the manufacturer provided panel. This put undue stress on the expensive connectors leading to premature wear and took up too much room in an already cramped cockpit. Additionally, the pilot wanted the option to add USB charging capabilities to the panel.
The Solution
Outcome
I created a system of interchangeable buckets that could support audio connectors, USB plugs, or any future expansion that could slot into cutouts in a carbon fiber plate. Carbon fiber was selected because of its high stiffness, light weight, and undeniable style. It was cut to size on a water jet cutter and the buckets were 3D printed and inserted.
In the end, the angled buckets provided the needed strain relief and routed the cables in such a manner to save crucial space in the cabin. The carbon fiber and 3D printed plate remains in active use replacing the older compromised fiberglass. The modular design also allows later expansion as deemed necessary.