Skills: Composites, SolidWorks
I manufactured carbon-fiber body tubes for the rocket by laying carbon fiber sheets and 2-part liquid epoxy over a mandrel. This process required precision to ensure the final body tube was a consistent diameter and had a smooth surface that was free from any defects, such as air bubbles or surface tears.
Hand-laid composite body tube
I also manufactured the fins of an airbrakes mechanism. This process included designing a 3D-printed a structural base, which was overlaid with carbon fiber and epoxy. The composite fins underwent several design and manufacturing iterations, including adjustments to the structural base dimensions and experimentation with different layup techniques, to achieve a uniform finish that accurately fit the airbrakes mechanisms. The final fins were sanded, filed, and drilled to remove excess material and ensure a precise integration into the airbrakes assembly.
Airbrake fins iterations
Airbrake fins layup
Composite fins integrated into airbrakes assembly
Additionally, I led the main assembly of the rocket, which included applying epoxy fillets to securely attach critical components such as the fins, boattail, and fairings. I also installed the nose cone using rivets and joined body components with bolts to create a structurally sound final rocket.
Applying fillets to fins
Boattail fillet
