Build Phases
The Cycle
Design & Simulate
We model the rocket in parametric CAD — adjusting nose cone profile, fin geometry, and body diameter until the simulation looks right. OpenRocket is our primary tool for predicting altitude, stability margin, and flight time. We iterate digitally until the numbers hit the ARC window before printing a single gram.
Slice & Print
Components are sliced with careful attention to wall count, infill pattern, and layer orientation relative to load paths. The body tube, fins, nose cone, and motor mount are all printed in-house on FDM printers. We weigh every print against our mass budget and re-slice if needed.
Assemble & Bond
Components are assembled using structural epoxy — fins are through-the-wall mounted into slots printed directly into the body tube. We verify CG and CP location physically with a balance point check, and compare against the simulated values before any motor is loaded.
Ground Test
Before flight day, we run through a full pre-launch checklist: parachute packing and ejection charge sizing, motor retention confirmation, and a final mass measurement. Everything is documented so we can trace any anomaly back to a specific build decision.
Launch & Debrief
On launch day, we follow range safety procedures and record every flight with a timer and altitude tracker when available. After recovery, the team debriefs: what matched the simulation, what didn't, and what changes go into the next iteration. Every flight is data.
Our Toolkit
Tools We Use
OpenRocket
Primary simulation environment. Used for altitude prediction, stability margin analysis, and ejection delay calculation.
CAD Software
Parametric modeling for all printed components. Geometry changes propagate instantly across the full assembly.
FDM Slicer
Controls infill density, wall count, and layer height — the levers that determine part strength and mass.
FDM Printer
All airframe components are printed in-house, giving us complete control over geometry and material choice.
Structural Epoxy
Used for all permanent bonds — fins to body tube, motor mount to airframe, and nose cone retention.
Digital Scale
Every component is weighed against the mass budget. If a print is over, we re-slice or redesign before moving on.