2022-2023 Payload Team Lead

During the 2022-2023 school year, I joined AERO’s leadership as the Payload Subteam lead. I was responsible for leading the design and construction of our payload experiment, integration into the rocket, and overall execution. I also led team meetings, make design and manufacturing decisions, and ensure proper payload systems integration with the rocket. The payload project was a versatile CubeSat deployer system, designed to deploy any combination of CubeSats up to 3U out of the rocket. To demonstrate this system, we built a 3U CubeSat to be deployed from the rocket just before the release of the rocket’s drogue parachute (~1200 ft). The CubeSat was equipped with multiple functionalities to demonstrate scientific potential including a “Seed-Spread” mechanism, onboard video footage, and live telemetry. At over 14 lbs and 16″ long, it’s my most ambitious project yet.

Based on the “U” standard size, the CubeSat model is a standardized form providing a streamlined platform for satellite-based scientific experiments and mission concepts. Our payload experiment significantly expands Duke AERO’s capability to develop innovative payload technologies that operate inside and outside of the rocket.

Design

Using SolidWorks and Onshape CAD software, I oversaw 2 teams designing the dispenser system and the CubeSat vehicle. I managed both teams to ensure that the CubeSat and the dispenser interfaced properly and could satisfy mission requirements. Most importantly, though, I was responsible for coordinating with other team leads to ensure the payload didn’t interfere with critical rocket systems and integrated properly. The payload fits into the forward airframe of the rocket just below the nosecone, which the CubeSat is ejected out of.

The dispenser uses a motor-and-belt-driven pulley system to propel the CubeSat out of the rocket at the desired altitude. At ejection altitude, a flight computer initiates the ejection sequence: releasing the CubeSat and propelling it out of the rocket. The CubeSat design is a fiberglass body that deploys an independent parachute after ejection. An onboard flight computer triggers a servo to release a hatch that deploys the parachute once clear of the rocket.

Manufacturing

All Payload components were manufactured in-house by myself and team members. Aluminum parts were precision-machined using Fusion 360 CAM and CNC mills, lathes, Electrical Discharge Machining (EDM), and waterjet. Additionally, non-structural critical components were 3D-printed in PLA.

The Payload’s electronics system consisted of a custom Printed Circuit Board (PCB) designed by the team, as well as a commercial flight computer and ESC. The CubeSat electronics were controlled using a Spresense microcontroller and digital servos.

I also designed and gave a presentation called Rocketry 101: Fundamentals of High-Powered Rocketry to help build foundations in rocketry and engineering for new members.

Check out my work in the previous year as Structures Engineer on our competition rocket, Coach 30k.

 

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