Personal Projects

Hybrid Rocket Motor - NP1

The NP-1 is a 2-inch diameter hybrid rocket motor under active development, designed to use paraffin wax fuel and nitrous oxide (N₂O) as the oxidizer. This project serves as a hands-on exploration of hybrid propulsion systems and reflects our passion for pushing experimental rocketry beyond simulation and into full system realization.

Design and Modeling

We use Onshape for all CAD modeling and calculate thermodynamic performance using RPA (Rocket Propulsion Analysis) and HRAP (Hybrid Rocket Analysis Program). Stress analysis is currently being conducted in Excel, allowing us to iteratively evaluate casing strength, bolt loading, and pressure vessel behavior.

Our motor is designed to produce an average thrust of approximately 100 lbf over a 5-second burn, based on current simulations. The injector head sourced from McMaster-Carr is adapted with a custom shroud to enhance atomization and promote uniform oxidizer dispersion into the fuel grain. We plan to incorporate a KNSB-based solid starter grain to assist with ignition stability and flame propagation during startup.

Testing and Development Plan

Our initial objective is to design, fabricate, and static fire test the NP-1 motor. The test setup will feature a load cell for thrust measurements and a remotely operated nitrous oxide tank that is plumbed to the motor bulkhead. The current focus is ground-based testing, with an emphasis on validating the combustion behavior, thrust curve, and overall feasibility of small-scale hybrid systems.

Challenges and Innovation

One of our biggest design challenges has been scaling down the injector system for such a compact motor. Off-the-shelf options are limited at this scale, which led us to prototype around a McMaster-Carr injector nozzle paired with a shrouded head to increase kinetic mixing and atomization. As a self-funded project, we’ve also had to make thoughtful tradeoffs between design optimization and cost, making resourcefulness a central part of our engineering approach.

Collaboration and Impact

The NP-1 is a joint project between myself and John Burkholder, a recent Mechanical Engineering graduate from ODU. We share co-responsibility for the design, modeling, and testing of this system. Beyond personal development, this motor has sparked interest among members of the ODU Rocketry Club who are excited about the potential of hybrid propulsion system. Our work aims to both deepen our academic understanding and demonstrate the feasibility of small-scale hybrid motors to the student rocketry community at ODU.

LEO - Level 3 HPR

LEO is my Level 3 capable high-power rocket that I plan to launch to secure my final NAR High Power Rocketry Certification. Standing over 11 feet tall and weighing 50 pounds fully loaded, LEO is expected to surpass 6,000ft altitude on its certification flight using an M class motor. LEO features dual redundant flight computers with a dual deployment parachute system. All features of the avionics bay including both flight computers and GPS tracking were installed and programmed myself to ensure LEO has a successful recovery. I anticipate getting my certification by the end of the summer in 2024 in which I will be able to further explore all areas of rocketry.

(Specifically I am very eager to work on developing and testing my own rocket fuel! This may either be through ODRC or a personal project)

Flight Computer

LEO utilizes dual redundant flight computers shown in the image above. More specifically, LEO uses an Altus Metrum Easy Mini and a Missile Works RRC3 flight computer. The main and secondary flight computers were both programmed to deploy a drogue parachute at apogee and a main parachute at 1,000ft altitude. To do this, I used AltOS software and hardware specific to each flight computer.

Using Fusion 360 modeling software I designed and printed the avionics sled in engineering resin using my own SLA 3D printer. I opted to create a custom sled to maximize the amount of internal volume I would have for future electronics. This would prove useful as I would go on to incorporate a independent GPS tracking system on a separate sled. Having sufficient interior space was necessary for two mechanical switches to be installed so that flight computers could be safely turned on once the rocket was lifted onto the launch rail.

Deployment Testing

Shown above is a night time deployment test for LEO's main parachute section. Conducting deployment tests is where I encountered the most set backs in as there were many cases of failed or insufficient deployment tests. Some of the main causes for failure were insufficient black powder for ejection, not properly checking continuity to e-matches, dead batteries, and improperly sealed vacuums. The image above shows one of the successful tests where I used 5g of black powder to break 3 4-40 shear pins in the upper section. I have since conducted multiple deployment tests to ensure LEO's parachute systems fully clear the vehicle and can deploy fully. Testing has concluded as I prepare for the certification launch of LEO this summer.

Note: All appropriate safety measures were taken to conduct safe and effective deployment tests with no risk to any property or personal damages.

Tubercle Surf Board Fins

Embarking on a personal project to enhance my surfing experience, I explored surfboard fin design by integrating tubercles for improved performance. Inspired by whale fins' efficiency, I aimed to replicate their benefits by adding tubercle ridges to surfboard fins' leading edge. Through self-taught skills in computational fluid dynamics (CFD) simulation, I conceptualized and 3D modeled custom fins, to validate their functionality. Transitioning to physical prototypes, I faced challenges with 3D printed resin fins, as their strength for surfboard applications was less then desireable. Seeking industry feedback, I approached leading surfboard manufactures in the local area where I lived.

After taking a break to learn new manufacturing methods, I was able to produce surfboard fins entirely out of carbon fiber using a "forged carbon fiber composite" technique. By layering chopped tow carbon fiber and reinforcing strands, I produced a significantly stronger and more durable fin. Using a compression mold helped to evenly disperse the carbon fiber and resin, allowing the parts to be made with very little equipment and no heat treatment requirements. This method not only increased the fins' structural integrity but also allowed for rapid prototyping as fins could be made every 8 hours, allowing for curing time. My new carbon fiber fins have shown promising results in preliminary testing, in which I plan to bring this fin design to more experienced surfers to test the added effects of incorporating tubercles to surf board fins.

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