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NYU's Rocketry Team
Payload Engineering Co-Lead
January 2024 - Present
Rogue Aerospace is the rocketry team at NYU that builds, tests, and launches a rocket to compete in the NASA USLI Student Launch competition. We are currently participating in the 2026 FAR Competition. In the competition, student teams from all over the country compete based on criteria that change every year. As a payload engineer, I'm responsible for designing the rocket's payload section, which contains the rocket's deliverables, whether satellites, astronauts, or cargo. Over the past year, I designed the payload's electronics bay, as well as 3D printed and post-processed parts for the 2024 competition season.
2025-2026
2025-2026
Electronics Bay
Electronics Bay
SpaceX Rideshare Visualization
For this year's electronics bay, my goal was to integrate a stepper motor, altimeter, motor driver, and an Arduino Nano within the space available in the nose cone, with a lead screw mechanism retained and running throughout the payload. Since the lead screw was to run through the center of the payload, I could not use the vertically stacked plate design from last year, as it may risk wires and electronics getting caught within the rotating lead screw. Inspired by the Transporter designs from SpaceX' Rideshare program, I decided to have a dome with its surfaces as mounting surfaces for the electronics.
An initial design was mocked up by another member. I verified the design with the assembly and verified the geometry with the electronic components. As seen in the figures on the right, the battery compartments protruded out of the nose cone. I verified the dimensions of this component and fixed it accordingly in the CAD. I also created pilot holes for heatset inserts on the surfaces to ensure an easier assembly after 3D printing the electronics bay. The length and diameter of the hole were sized according to Spirol's Threaded Inserts Design Guide.
Protrusions from the Nose Cone
Electronics Bay Initial Print
The initial design was completed and printed using ABS. After integrating the electronics bay onto the nose cone, I realized that there were difficulties fitting the assembly in, as I did not take into account the packing of the wires within the nose cone. I also realized that the electronics bay did not need to be in a pyramidal shape. A rather flatter shape would work, as it keeps vital components closer to the center of the rocket while continuing to shield them from the lead screw in the middle. Thus, I redesigned the electronics bay to look like the final design below.
The final uses a more flattened structure, which also saves on weight and manufacturing time. It still contains pockets for the 9V batteries and electronic components on the other side. I also designed a retaining ring to epoxy onto the PVC tube shown in gray. This acts as an attaching mechanism of the electronics bay to the rest of the components in the payload. The electronics bay also contains sleeves to insert the nuts to retain the threaded rod.
Section View CAD
Isometric View CAD
Electronics Bay in Assembly
The electronics bay was assembled using heatset inserts, which were installed using the correct type and size according to the design guide. Standouts were used to allow for some room on the pin side of the electronics. I utilized zip ties to manage the cables.
Payload Subsection CAD
Manufacturing Processes
Manufacturing Processes
I coordinated with members of the payload team and the aerostructure subteam to conduct a carbon fiber and fiberglass layup. For the payload subteam, I conducted the pilot run for the nose cone layup, taking note of important processes such as epoxy and hardener ratios, the amount of carbon fiber layers needed, and the ordering of carbon fiber layers. I documented all of these details in a standard operating procedure to translate the manufacturing process into repeatable steps in the future. I also consistently updated these documents to adjust to changes in the manufacturing process. For instance, when 3 carbon fiber sleeves were determined sufficient for the layup, the steps were updated accordingly.
Carbon fiber sheet cutting
Waterjetting of nose cone tip washer
2024-2025
2024-2025
Electronics Bay
Electronics Bay
The payload for the 2024-2025 season included successfully landing the payload on the rocket, taking appropriate sensor data such as temperature, maximum apogee, etc., and transmitting the gathered data via radio. I was responsible for designing the electronics bay for the payload in which these vital sensors would sit. I designed the electronics bay using SolidWorks and prototyped the design using a laser cutter and 3D printers. I continuously optimized the electronics bay in order for it to be easily accessible, easily assembled, and structurally sound.
Electronics bay with the rest of payload assembly
Electronics bay
For the 2025 USLI season, I was responsible for designing and manufacturing the electronics bay of the rocket's payload. The electronics bay is the platform that would house all of the electronics components, sensors, and batteries associated with the rocket's payload. I designed the electronics pay with several factors in mind including weight distribution, space efficiency, and durability.
Other electronics bay designs were considered. First, I considered having the plates horizontally layered rather than vertically layered. This would allow for the landing legs to be extended near the nose cone section, as there would be open space near the center of the electronics bay. However, this could lead to an unbalanced weight distribution of the payload as certain electronic components weigh more than others. Thus, heavy components such as the battery might cause the rocket to sway to one side during launch when it is placed closer to one side than the other. These factors were considered and organized using a trades study, as seen on the right.
Electronics bay for subscale launch
The initial version of the electronics bay was manufactured for the subscale launch in 2/3 of the intended size. As I manufactured and assembled the electronics bay, I faced several issues. Firstly, the use of threaded rod level the electronics bay shelves made it timely and complicated to assemble. 6 nuts and washers needed to be screwed into the threaded rod for each shelf. This is also difficult to disassemble in case electronics need to be taken out of the electronics bay or other parts need to be added. Secondly, it made it difficult to tell the height at which the shelf must be placed. Nuts would sometimes loosen, and the shelves would no longer be at the intended height of 2.4 inches from one another.
I designed a new electronics bay design that would overcome this issue. It would have vertical wooden shelf holders that would have slits. I also made slits on the shelves so that they would fit with the shelf holders. This makes it so that nuts and washers need to be used to keep the shelves stable. It also enables easy assembly and disassembly of the electronics bay without sacrificing the structural integrity of the electronics bay. The shelves simply need to be slotted into the shelf holders in order for them to be completely assembled. This also resolves the second issue of shelf heights. Because shelves are maintained at the height at which the slit is cut out from the shelf holders, the height of each shelf can be easily determined. As a result of this change, the team was able to successfully manufacture and assemble the electronics bay before the demonstration flight deadline. The electronics bay also remained structurally intact throughout the demonstration flight.
New electronics bay design without threaded rods
Electronics Bay Engineering Drawing
Payload Assembly
Payload Assembly
Payload Assembly CAD Render
I worked closely with other members of the payload team to complete the full CAD design of the payload. Assembling components various members on the team had worked on, it was crucial for me to properly manage the space within the payload and ensure all components are located where they are supposed to.
Manufacturing and Testing
Manufacturing and Testing
For the 2024 USLI season, I gained hands-on experience with building a rocket. I used tools such as the drill press and cordless drill, as well as handheld shop tools to assemble parts of the payload as well as the frame of the rocket. I also utilize the UltiMaker Cura 3D printer, the Fortus 3D printer, and the Tormach CNC machine to manufacture crucial parts of the rocket, including the nosecone, bulkhead, and STEMnaut plates. A test that we conducted on the rocket's payload was the vibrations test. The payload was attached to an electrodynamic shaker which vibrated the payload structures at varying frequencies. Afterward, the payload was inspected for damages, deformations, or detachments. I was responsible for observing the test and writing detailed documentations on the results of the test.
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