Lead engineer for a 586 lbf N₂O/HTPB hybrid rocket feed system targeting a club record 20,000 ft apogee. Designed full oxidizer plumbing at 750 psi MEOP, performed discharge coefficient modeling, FEA-validated endcaps and brackets, and led cold-flow and static fire campaigns.
Design complete plumbing architecture (tank, valves, relief, fittings) rated 750 psi MEOP
Model discharge coefficient (Cd) and pressure losses using Python + experimental validation
FEA-validate endcaps and brackets to required margins of safety
Execute hydrostatic proof, cold-flow, and static fire test campaigns
Selected components (ball valves, pneumatic actuators, check valves) and laid out the plumbing schematic to deliver N₂O at 750 psi while maintaining simplicity for field operation. Designed lightweight aluminum endcaps for the pressure vessel and support brackets for structural integration.
Built a flow model to predict steady-state and transient pressure losses. Performed discharge coefficient (Cd) calculations for each orifice and fitting, validating against published data from peer-reviewed sources. FEA-validated all structural components under combined loading (internal pressure, bolt preload, bending). Factor of Safety on endcaps: 2 (yield), 2.5 (ultimate).
Machined aluminum endcaps and brackets, then executed hydrostatic proof testing at 1.5× MEOP (1125 psi). System passed with zero leaks. Led cold-flow campaign validating oxidizer flow rates, system timing, and valve sequences, each run instrumented with pressure transducers.
Cold-flow / water-flow test
Coordinated static fire integration with motor and avionics teams. Launch day: 586 lbf thrust confirmed. System delivered stable combustion and record apogee.
Reaction to the launch
Launch camera
Hotfire test
The system performed flawlessly under test and in flight. Hydrostatic proof testing confirmed structural integrity at 1.5× operational pressure (1125 psi). Cold-flow campaign validated all flow paths and valve timing. Static fire delivered 586 lbf sustained thrust and achieved 13,400 ft apogee. This was real engineering: pressure testing, iteration from FEA to hardware, instrumented testing, and flight-proven performance. The work proved that with rigorous analysis and testing discipline, a student team can design systems that operate at professional aerospace standards.