RPL Project Daedalus / Lead Solid Motor Rocket Engineer

Initial Design using OpenRocket

Final Design using SOLIDWORKS

Design

The design process began with preliminary modeling using OpenRocket, where I defined key parameters such as motor selection, flight profile, stability margin, and mass distribution. This allowed for initial validation of the rocket's performance and apogee estimation.

I then translated the design into a detailed CAD assembly using SOLIDWORKS, where I developed each rocket section individually — nose cone, fin can, body tube, parachute, motor, and avionics bay — and ensured part-level compatibility for manufacturing and integration.

Design Reviews (presented to over 40+ engineers):

Preliminary Design Review (PDR)

Critical Design Review (CDR)

Nose Cone

Fin Can

CAD Parts

Body Tube Joint

Main Body

Parachute Chamber

Avionics Bay

SOLIDWORKS Flow Simulation / Finite Element Analysis (FEA, CFD)

Stress Simulation

Strain Simulation

Using SOLIDWORKS Simulation, I conducted both stress and strain analysis on the rocket body and fin assembly to ensure the design could withstand aerodynamic loads and thrust-induced forces during launch.

The stress simulation evaluated the rocket under maximum expected forces during liftoff and acceleration.
The strain simulation helped assess deformation risk and guided material/thickness choices.

In addition, I performed Flow Simulation (CFD) to analyze aerodynamic pressure and ensure minimal drag while maintaining stability throughout flight.

Avionics & Manufacturing

Avionics Bay CAD assembly

Initial Avionics Configuration using Arduino sensors

Avionics

I programmed an Arduino Nano to log synchronized flight data from a BMP388 pressure sensor and BNO055 IMU to a MicroSD card. The code handled flight detection, delay timing, and CSV formatting. After prototyping the system on a breadboard, I soldered all components to a compact PCB for secure, vibration-resistant connections.

View my Code on GitHub

Manufacturing

I oversaw the full manufacturing process of the rocket, combining 3D printing, machining, and manual assembly. Using SOLIDWORKS, I designed all major components—including the nose cone, fin can, body tube, parachute, motor, and avionics bay—for precise fit and modularity. I 3D-printed PLA parts such as the nose cone and avionics bay. Each component was assembled and fastened with careful alignment to maintain aerodynamic integrity, and the full airframe was fitted, tested, and refined to ensure it met launch and recovery requirements.