Student ProjectsNUSTARS Rocket Team (2023-2024)
Project Manager
Andy Wehmeyer, Student
Amount Requested
$5,000
Summary
Northwestern University’s Space Technology and Rocketry Society (NUSTARS) is Northwestern’s premier aerospace-engineering student organization. The main project of the 2023-2024 launch season is to design, build, and fly a novel rocket for the NASA Student Launch Initiative (NASA SL). This challenge focuses on delivering an electro-mechanical payload designed to accomplish a specific objective to a target elevation around 5,000 feet and introduces students to a wide range of engineering design and manufacturing skills. Previous objectives include designing a deployable rover to autonomously navigate via GPS or a self-righting camera system to stream data to a ground station. This project encompasses the full design timeline including brainstorming, design, manufacturing, iteration, and validation. This culminates in a competition where we will showcase a final full-scale launch of our launch vehicle and payload which is expected to measure 10 feet long and weigh 35 pounds. We will evaluate performance by comparing launch data to predicted simulations generated on computational fluid dynamics software and judge the reliability of the payload in achieving its target goal. In addition, the team’s design process and documentation will be evaluated against other university teams, offering useful feedback and opportunities to learn from peers in the field. NUSTARS aims to supplement the undergraduate classroom experience with student-directed learning opportunities. NUSTARS offers an invaluable early entry into the practice of aerospace engineering, from design to manufacturing, for students at any grade level. NUSTARS prides itself on being inclusive of all students regardless of their prior experience level and runs internal training sessions to educate new members so that they may contribute equally to the team. By offering project based learning opportunities, students gain industry-applicable skills. By funding this project, the Murphy Society will be investing in the future of aerospace opportunities available for Northwestern students.
Planned Activities/Investments
The project cycle of the Rocket Team unfolds in parallel to the NASA SL timeline. New club members begin by building certification rockets to be introduced to the basics of high power rocketry language and design principles. Following certification, these members advance their skills and experience by contributing to improvements to individual subsystems of the team’s legacy rocket, Theseus. These projects give students a stake in real engineering challenges and familiarize them with design and simulation software required for future contributions to the team. The is divided into sub teams that work in parallel on developing and prototyping initial payload solutions and launch vehicle subsystems. Although the design challenge has not yet been announced, we plan to begin the year by exploring development of a filament-wound carbon fiber airframe in-house, our homebrew telemetry package, and novel fin-clamp designs. These subsystems will be continuously prototyped during Fall quarter, evaluated for feasibility during the critical design review in Winter quarter, and integrated into the launch vehicle prior to competition which concludes with a full-scale launch in April. Our rapid- prototyping approach to solving structural, mechanical, and electronic challenges ensures that the final launch vehicle deliverable will both meet the competition challenge requirements and demonstrate the successful development of new in-house systems. The Rocket Team engages with a challenge unlike any other in the field, tackling a project that requires integration of multiple interconnected subsystems that each affect the performance and reliability of the final launch vehicle while constrained to a system that must soar a mile high under incredible dynamic loading conditions.
Impact
The aerospace concentration is a growing area of interest for undergraduate students at Northwestern. Our club serves an invaluable function for the department and students; providing undergraduates with hands-on aerospace design challenges prepares them for a future in the aerospace industry and research and fostering a robust aerospace community further justifies departmental commitment to aerospace while helping students explore different fields. With the funding awarded by this grant, we will be able to support more advanced aerospace projects for an even greater number of students. The impact of the engineering work completed will be measured quantitatively in comparison to other schools with developed aerospace programs through NASA SL competition ranking. The impact on Northwestern’s aerospace community can be quantified through the number of students declaring an aerospace concentration and through NUSTARS club enrollment. Additionally, the success of the project also involves qualitative factors such as enthusiasm for future projects and teaching the next generation. Data in this regard will be collected quarterly with an internal annual census review.
Sustainability
Although the NASA SL project varies in its objective year to year, NUSTARS is committed to building a knowledge base in the field of high power rocketry and expanding Northwestern’s stake in the aerospace industry. NUSTARS represents a means to serious engagement with aerospace-focused engineering challenges for Northwestern undergraduate students. Given that there is departamental interest in expanding the aerospace program, there is a symbiotic relationship between the stability of both these programs. NUSTARS is also helping develop industry-standard skills and technical knowledge for students. The systems established to document advances of legacy projects and teach new members enables a continuity of engineering design work and high level performance every year without needing to re-invent processes or experience. NUSTARS is actively growing its network of corporate partners and alumni invested in the success of the program. We currently have a network of 100+ alumni who continue to share their wisdom and offer recruiting sessions with current team members. In the past, we have received $13,000+ from external partners as well as in-kind donations from OnShape. We are currently looking to expand our funding sources in order to be sustainable for years to come.
Deliverables
The main deliverable for the project will be the final launch vehicle and payload that meets the competition objectives and builds upon design iterations made throughout the year. This design will be validated at the competition launch in April. Other deliverables include the Design Proposal, Preliminary Design Review (PDR), Critical Design Review (CRD), Flight Readiness Report (FRR), and Post-Launch Assessment Review (PLAR) reports as well as photos, videos, and comprehensive simulation analysis.
Budget Overview
- $3,000 Launch Vehicle: Launch vehicle structure including airframe, fins, bulkheads, payload integration.
- $1,000 Launch Vehicle Recovery and Data Packages: Custom avionics package, redundant commercial avionics systems, parachutes, separation mechanism.
- $500 Subscale Launch Vehicle: Prototype launch vehicle for payload, electronics, and structural design validations.
- $3,000 Payload Mechanical/Electrical: Rapid prototyping tools, custom electronics, mechanical parts.
- $500 Safety: Respirators for composites manufacturing, safety cabinets, fire extinguishers.
- $1,000 Test Launch Transportation: Car rentals for (3) test launches.
- $5,500 Competition Transportation: Van Rentals, lodging, and expenses during NASA SL competition.
Total: $14,500
Note: this budget represents an outline of the project cycle as a whole. In submitting this document we understand that there is a cap to the Murphy Grant and the restricted areas (ie. no travel) it can be applied to. If awarded, this grant would contribute primarily to launch vehicle costs.
Advisor Sign-off
NU Stars - Nick Marchuk, Mechanical Engineering