Airframe Design - Waterloo Rocketry
Overview
Helped build composite airframe (fin-can/fuselage) for Waterloo Rocketry Aurora rocket. Controlled mass properties and geometry for predictable flight stability.
Results
Iterated laminate schedules in ANSYS Composite PrepPost; checked strength/buckling and ply drop-offs. Modeled interfaces and tolerances in SOLIDWORKS; created layup maps, ply books, and cure cycles. Executed wet layup with vacuum-bagging; trim, drill, and fit-up operations on fin-can/fuselage. Built alignment jigs and datums; documented work instructions and QC checkpoints. Performed manual sanding and finishing, and hardware installation to spec. Reduced structural mass by ≈2% while maintaining safety factor at 60 g axial load (analysis). Produced documentation that onboards new members quickly and preserves process knowledge.