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Solar Flare — Engineering Roadmap

This roadmap turns the existing V1.3 design into a measured, reproducible POC before further feature work.

Current engineering baseline

  • Public design documentation: V1.1 → V1.2 → V1.3.
  • A complete offline POC package exists with SolidWorks assemblies/parts, STEP export, STL exports, BOM and fabrication notes.
  • Current POC lens baseline: Edmund Optics #43-013, 139.7 × 139.7 mm (5.5 × 5.5 in), EFL 254 mm (10 in), acrylic, uncoated, 85% typical transmission, 80 °C maximum operating temperature.
  • The offline final-POC BOM dated 2026-01-27 identifies the lens by dimensions and focal length (5.5 × 5.5 in, 10 in focal length), which is consistent with #43-013. The BOM still needs an explicit manufacturer part number before P0 can close.
  • The same BOM specifies a nominal Ø12 retaining ring with +0.2 to +0.3 mm recommended internal clearance (12.2–12.3 mm). This documents the intended clearance, but does not yet prove that the final printable geometry implements it.
  • An older candidate lens (#32-686, 170.18 × 170.18 mm, EFL 304.8 mm) exists in the engineering archive but is not the current final-POC baseline.
  • The current final POC STL package spans roughly 709 × 466 × 709 mm in its export coordinate frame. This is an engineering-envelope check, not a certified product dimension.

The public ~18 W figure remains an estimate until calorimetric or equivalent measurements are published.

P0 — Freeze one buildable POC baseline

Before adding new features:

  • Confirm the final assembly, STEP and STL exports all correspond to the same configuration.
  • Confirm #43-013 is the lens used by the BOM, CAD support and test plan. Partial evidence: the offline final BOM matches #43-013 dimensions/EFL, but names no manufacturer part number; CAD support and test-plan checks remain open.
  • Resolve all historical ×3 / larger-lens references so they cannot be confused with the current POC.
  • Check the 0.2 mm-clearance printable variant against the final assembly. Partial evidence: the offline BOM explicitly recommends 12.2–12.3 mm ID for the nominal Ø12 retaining ring; exported/final CAD geometry still needs verification.
  • Produce a single definitive BOM revision with materials, quantities, mirror substrate/film and adhesives.
  • Record the intended hinge-axis materials and flexible-cap solution.

Exit proof: one archived build package with a revision ID, matching CAD/export/BOM/lens reference.

P1 — Mechanical and safety validation

Priority is safe control of concentrated sunlight, not aesthetics.

  • Verify all four reflector hinges move through their full range without interference.
  • Validate the synchronized opening/closing mechanism under realistic cable tension.
  • Add/verify positive open and closed stops.
  • Ensure a fast, reliable way to remove the focused beam from the target.
  • Verify the lower aiming mirror cannot redirect the focus onto the structure in normal use.
  • Replace load-bearing hinge pins with metal where required.
  • Keep flexible caps/bushings in TPU/TPE or use commercial retaining hardware rather than stressed PLA.
  • Define a safe exclusion zone around the focal path.

Exit proof: repeated open/close cycles without jam, loss of alignment, unsafe beam path or structural damage.

P2 — Optical and thermal test campaign

Do not infer output power from collection area alone.

Measure at minimum:

  1. ambient conditions and solar irradiance;
  2. aperture/configuration used;
  3. focal-spot size and position;
  4. useful thermal power with a controlled absorber or calorimetric target;
  5. temperature at the absorber, lens mount and nearby polymer parts;
  6. sensitivity to angular misalignment;
  7. performance with and without the lower deflector mirror;
  8. shutdown/defocus time.

The acrylic Fresnel lens is specified for 80 °C maximum operating temperature. The test setup must verify that the lens and mount remain below their safe operating limits.

Exit proof: a repeatable test sheet with raw measurements, uncertainty and at least three comparable runs.

P3 — Reconcile claims with measurements

After P2:

  • Replace estimated power claims with measured ranges.
  • Publish the exact tested configuration.
  • Separate incident solar power, optical throughput and useful delivered thermal power.
  • Document losses from reflector alignment, lens transmission, beam clipping and the deflector mirror.
  • Remove or qualify any use-case claim that exceeds the measured envelope.

P4 — Public build package

Only after the POC baseline is stable:

  • Publish validated STEP/STL exports and a clean BOM.
  • Decide whether to publish native SolidWorks sources with the same validated revision.
  • Add assembly instructions and printable-part orientation/tolerance notes.
  • Add a reproducible test protocol and measured results.

P5 — Downstream projects

SolarLift and SolarWell must consume a measured Solar Flare thermal envelope, not a nominal or theoretical figure.

A downstream design should state:

  • tested input configuration;
  • useful thermal-power range;
  • duty cycle / tracking assumptions;
  • allowable target geometry;
  • thermal and alignment limits.

No downstream performance claim should exceed that measured envelope without an explicitly larger collector or additional energy source.

French summary

Priorité : figer un seul POC cohérent, le construire, vérifier la mécanique et la sécurité, puis mesurer réellement la puissance utile. Les améliorations et intégrations SolarLift/SolarWell viennent ensuite. La lentille POC actuellement retenue est la #43-013 (139,7 mm, focale 254 mm) ; l'ancienne piste 170,18 mm / 304,8 mm reste historique tant qu'elle n'est pas réadoptée explicitement.