Aurora Rocketry

MEET THE TEAM

STRUCTURE

OVERVIEW

The Structures Department is responsible for the design and CAD software development of nearly all components of the experimental sounding rockets developed by Aurora Rocketry.
The process involves close collaboration with each of the individual departments involved in the active development of the rocket. The departments provide the general guidelines and requirements that we have to follow and based on which we entirely develop a lightweight structural design accurately optimized through meticulous simulation work aimed to obtain the best performance balance.

CAD DESIGN and DRAWING

The department engages in a phase of close collaboration with all of the team's departments to define all of the preliminary requirements needed for the final design. The work is then subdivided in subprojects, each dedicated to the respective department: the subprojects will work to develop original and innovative designs and solutions to best address the challenges posed by the project's technical requirements. The members will design and engineer the entire rocket structure that supports and surrounds all of its subsystems. In-depth research is conducted on materials sciences (metals, composite fibers, or 3D printing) and manufacturing techniques.

LOAD SIMULATION and OPTIMIZATION USING FEM ANALYSIS

Once preliminary CAD models are obtained, approximated flight load data provided by the Aerodynamics, GNC , Propulsion and Mission Analysis departments is used. The members perform a series of simulations using the finite element method. Such simulations are aimed to obtain precise information on maximum deformations and structural strength of the components. The simulation phase is crucial for maximizing the aircraft's mass, tracking the loads to properly distribute the structural reinforcements, achieving maximum performance.

PROTOTYPE CONSTRUCTION

Once a final CAD model of the various subprojects has been obtained, we proceed to the production of test components, where necessary, to test the prototype's most important systems in collaboration with the other departments. If the testing campaigns are successful, the sounding rocket is built utilising cutting-edge production methods, such as composite materials and CNC machines.

FINAL INTEGRATION

The prototype is assembled and finished by department members making use of our technical facilities: they will finish the components manufacturing by manually refining them and then proceed with their final assembly and integration. The final rocket integration process has to be carefully executed by following special checklist pre-made by the department to ensure that the protocols required by the competitions in which the association participates are satisfied.