Mission Objective:
Successfully launch Cal Poly’s first liquid bi-propellant rocket and achieve full recovery with minimal damage.

Recovery System:

• Dual-parachute deployment

  • Drogue chute deployed at apogee

  • Main chute deployed at 1,000 feet altitude

• Rocket must return via main chute with nosecone and drogue securely tethered to the airframe

Post-Flight Requirements:

• Rocket must be recoverable and locatable after launch

• No structural damage compromising future flight capability

• Acceptable minor damage includes:

• Fin breakage upon landing

• Nozzle impact damage

Flight Instrumentation:

• Altitude tracking via two commercial off-the-shelf (COTS) components

Requirements

Test Stand

I was primarily responsible for designing and fabricating the rocket test stand, ensuring full integration with electro-mechanical components. The assembly featured an I-beam structure, linear rails, a load-bearing support, and a base plate. The rocket tank mounted to the linear rails, enabling controlled motion along a single axis, while the manifold secured to the load-bearing support via an eye bolt and load cell for thrust measurement and structural integrity. FEA was also performed on the tie down straps to ensure safety under hard start conditions.

I designed the load-bearing support to be precision-cut from ¼″ steel plate using a water jet and assembled through MIG welding. The base plate was welded directly to the I-beam structure. The design was engineered to withstand three times the expected thrust load, with structural integrity verified through hand calculations and FEA. Additionally, I contributed to fabricating the ignition line cutter system, machining precision pistons on a lathe to meet tight tolerances."

Manufacturing

Top Skills Utilized

• Finite Element Analysis (FEA)

• Water Jet

• MIG Welding

• Lathe

• Fusion 360

Takeaways

This project deepened my understanding of component manufacturing and designing for high factors of safety. I gained valuable experience interpreting detailed engineering drawings and actually manufacturing the parts. If I were to revisit the design, I would improve test stand mobility and integrate the base plate with ground anchors to eliminate the need for tiedown straps. I would also dedicate more attention to the recovery parachute system, as our initial deployment failed.

Check out our ballistic recovery at 15,300 ft!

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