I worked as a design engineer intern at a rapidly growing space startup, Manastu Space which manufactures affordable sustainable technologies like green propulsion and debris collision avoidance systems for satellites. My immense contribution led to improved productivity and performance of a few processes in the sub-system.
Design optimization:
After intense research on injector designs by doing literature surveys. I came up with a novel design idea, and so did the injector design optimization of a previous design which was part of a hydrogen peroxide-based monopropellant system. On optimizing the design, the injector flange’s mesh breakage decreased drastically while firing at a ground setup.
Design of mechanical components:
I designed various mechanical components using Solidworks which are integral parts of the thrusters of green propellant systems for satellites to avoid collision with space debris. One of which includes, designing of bending fixture that is used for making spiral-shaped injector capillary tubes. This fixture improved the utility, repeatability, and performance of the injector during both continuous and pulse-mode firing. Later, I designed a 2-litre propellant tank which is used in the ground test setup.
Experiments:
I performed a few experiments on finding the impact of positive loading using helical springs on a vibration-settling of the catalyst bed.
Simulations:
I have performed thermal and structural simulations in Ansys to validate the designs of the copper flange which was coupled to the injector flange to transfer the heat away from it, in order to avoid mesh damage which was spot welded on the injector flange. This led to a 100-degree Celsius drop across the injector flange and showed improved performance.