Falcon 9 Rocket Payload Fairing
In July of 2011 I began working at Space Exploration Technologies (SpaceX) as a structures engineer in the payload fairing design group. A payload fairing is a protective shell that encapsulates the rocket's payload (e.g. satellites, space probes, etc). These objects are designed for operation is space, where it is not subject to atmosphere or gravitational forces, and is thus not required to withstand strong forces or winds when in operation. This usually results in rocket payloads being very delicate objects, having large antennas, solar panels, and foils on the exterior, which would not be able to withstand the tremendous aerodynamic forces of a rocket launch. This is why for the duration of flight in the atmosphere, a protective shell (the fairing) encapsulates the payload to shield it from aerodynamic forces. Once the rocket is out of the atmosphere, the fairing is no longer needed, and is jettisoned to reduce the mass of the vehicle as soon as possible, and to expose the payload for eventual release from the second stage.
The fairing first flew atop the Falcon 9 V1.1 rocket from Vandenberg AFB on September 29th 2013. The fairing remained intact and separated cleanly from the 2nd stage. It has since been flown on over 200 flights.
As a structures engineer at SpaceX I was responsible for:
The structural connections holding the two fairing halves together, and various other metallic and composite structural components in the fairing that are too specific to list here.
Structural analysis of these components, both at a subscale, and at full scale, depending on the size and nature of the component.
Reporting of structural margins and completing load case design and qualification of metallic and composite components.
Working with manufacturing engineers, planners, technicians, and vendors to ensure products are manufactured on time and per specifications.
First flight of the Falcon 9 V1.1 rocket, showing the fairing riding on top (source: wikipedia)
Below are some more specific accomplishments:
Development of a method of bonding structural components to large composite structures, reducing assembly time, part count, and cost by more than 50%.
Developed a methodology for analyzing 3D element meshes locally within large 2D element meshes in FEMAP, increasing the validity of the model compared to subscale models while minimizing the impact on analysis time.
Designed a high-pressure pneumatic actuator, quick release mechanism, and various bonded and bolted interfaces.
Parametric matching of part geometry to uneven laminate contours to ensure a uniform bond thickness.
Created GD&T-based assembly and component level drawings per ASME Y14.5.
Performed analysis and mitigation of tolerance stackup in assemblies.
All designs are in production and have completed successful flights aboard the Falcon 9 V1.1 rocket.