Last Updated: 5/6/23 Jason
This SOP provides a guide to safely manufacture and assemble battery segments of the GR23 electrical vehicle. Some of the information is compiled from the following sources.

• Electrical Insulating PPE Guide

• Electrical shock & arc flash
• Short Circuits
• Electrical Insulating PPE
• Electrical Insulating Tools
  • Clear workspace of non-insulated tools

Battery assembly should take place on one of the workbenches in the Innovation Workshop in Elings 2442.

Safety and Materials section applies to both the Trotec and Rayjet Laser Cutter

• Safety considerations, how they can occur, and how to avoid electrical accidents
• Battery segment drawing and pictures
• Machining of insulation panels

This laser engraving system contains a class 4 carbon dioxide (CO2) laser that emits intensive and invisible laser radiation. Without safety precautions the direct radiation or even diffuse reflected radiation is dangerous!

• Always wear safety glasses when using the machine.
• Always work with the machine cover closed.
• NEVER leave the laser machine alone when running a job. If you do need to leave,
• The machine door must be left open while you are away.
• Do not store any flammable materials in the inside of the device or in the immediate vicinity of the device.
• Remove leftovers of previously produced materials before running a job.
• A fire extinguisher/fire blanket must always be handy as the laser beam can ignite flammable materials.
• Metals, particularly un-coated aluminum, copper, silver and gold, cannot be processed with the laser and lead to high reflections of the laser beam. If needed, metals can be coated with a paint/tape which chemically bonds to the surface when engraved.
• Before processing materials the user must verify whether harmful materials can be generated and whether the filter equipment of the exhaust system is suitable for the harmful materials.
• PVC (polyvinyl chloride) must under no circumstances be processed with the laser.
• Looking directly into the laser can cause retinal damage.
• Confirm that the fume collection system is running whenever the laser is cutting or engraving.

Always check materials list BEFORE attempting to cut/engrave a material. If unsure contact IW Staff.

Allowed Materials

Plastics:

• ABS (acrylonitrile butadiene styrene)
• Acrylic (also known as Plexiglas, Lucite, PMMA)
• Delrin (POM, acetal) — for a supplier, try www.mcmaster.com.
• Kapton tape (Polyimide)
• Mylar (polyester)
• Nylon (melts badly)
• PDMS
• PETG (polyethylene terephthalate glycol)
• Polypropylene (PP) — melts somewhat
• Styrene
• Two-tone acrylic — top color different than core material

Foam:

• Depron foam (often used for RC planes)
• EPM
• Gator foam (foam core gets burned and eaten away compared to the top and bottom hard shell)

Other:

• Cloths (leather, suede, felt, hemp, cotton)
• Magnetic Sheets
• Papers
• Rubbers(neoprene, etc supplier try: ​mcmaster.com​)
• Woods(MDF, balsa, birch, poplar, red oak, cherry, holly, etc. supplier try: ​midwestproducts.com​)

Prohibited Material

• Metals​ (our laser cutters are not powerful enough nor setup to cut through metals and attempting to do so could damage the machine)
  • Metals (cannot be engraved however a certain type of paint/tape which chemically bonds with the metal may be used to mark materials)
• Polycarbonate​ (P