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Rocket | High Power Rocketry

Date

August 2024

The GMU Rocketry Club is designing and building a high-powered competition rocket for the "Battle of Rockets". This project, supported by club resources, university labs, and sponsor partnerships, provides members with real-world aerospace engineering experience while showcasing student innovation in rocketry. We usually tackle tasks either by ourselves or in small teams, depending on what still needs to get done.

CAD (Computer-Aided Design)

Software & Tools:
Onshape is a super handy cloud-based tool that doesn’t require any installation and allows teams to collaborate easily. It’s free for students with a school email. It has parametric modeling, which makes tweaking dimensions for different iterations a breeze. When it comes to competitions, Onshape is great for designing things like fins, nose cones, and motor mounts. Plus, it has built-in tools for simulating aerodynamic loads. I love using the version control feature to keep track of the changes my teammates make on our projects. It helps me stay updated on how everything’s coming together. Sharing folders with the team for real-time feedback is also a huge plus.

3D Printing

Materials:
ABS is a popular thermoplastic known for its great heat resistance, which makes it perfect for parts that sit close to motors or any hot spots. It’s stronger than PLA, so it’s a solid choice if you need something durable. Just keep in mind that printing with ABS can be a bit tricky because it has a tendency to warp as it cools, so you might need to tweak your settings or use a heated bed to get the best results.

Software and Tools:
Bambu Studio is a handy slicing software that makes creating 3D prints a breeze. It offers quick and dependable support structures and various infill patterns, so you can easily customize your prints. The user-friendly interface lets you manage settings without a hassle, resulting in better print quality. Plus, it generates unique support designs that save material and make cleanup easier, making it great for both newbies and more experienced 3D printing fans.

Fiberglass

Materials:
We picked fiberglass for making our composite parts because it offers a great strength-to-weight ratio, which is perfect for tough components like fin cans, motor mounts, and bulkheads where we need rigidity and durability. Unlike 3D-printed plastics or wood, fiberglass doesn’t flex, delaminate, or get damaged by high heat, like what happens when the ejection charge fires. Plus, it’s non-conductive, so it won’t interfere with avionics. With a one or two layer- fiberglass bodytube, we can match the strength of aluminum but weigh half as much, which means we can use the extra weight for payloads or larger motors. Its smooth finish helps reduce drag compared to 3D-printed parts. In competitions, fiberglass really shows off innovation, making our designs more reliable and boosting our score potential by reducing mid-flight failures that often happen with all-3D-printed setups. Just remember to take safety seriously—wear gloves and masks and ventilate the area while working.

Laser Cutting

Materials:
Whenever I was assigned to laser-cut wood, I had the role of doing the fins because it gives you super precise cuts, which are important for making sure everything lines up correctly.

Software & Tools:
I used LightBurn to get identical parts every single time, and that helps with aerodynamics, giving you better stability and higher altitude. Plus, fewer assembly headaches mean you can build things faster. It’s also quicker to laser cut than to 3D print.When it comes to weight, laser-cut wood fins tend to be lighter than 3D-printed plastic ones. And in terms of strength, layered wood or acrylic can handle shear forces better than standard 3D prints.

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