The CubeSAT-Adorned Rocketry Masterpiece, or CARM, was the Tufts Rocketry Team's first-ever entry into the Spaceport America Cup. This 11ft tall, 6in diameter rocket successfully flew to ~9800 ft on an N2600 motor.
As a member of the mechanical team, I contributed to the manufacturing of some critical components, including the fins, switch band, avionics bay brackets, and thrust plate. The fabrication of these components forced me to learn about composite manufacturing and metal machining with manual mills and lathes.
CARM featured a dual-deploy recovery system. At apogee, the booster section splits from the rest of the rocket and releases a drogue parachute. This parachute slows the descent of the rocket considerably, allowing the larger, main parachute to deploy later on and minimizing the chances of any failures in the recovery system. The dual deploy method is also desirable because it restricts the cross-range distance of the flight. If the main parachute deployed at apogee, the rocket could float far away, making recovery much more difficult.
The primary body tubes that transfer the loads from the motor up the rocket were made of filament-wound G-12 fiberglass. This material was selected primarily due to its high strength-to-weight ratio. The commercial availability, low cost, and RF transparency also made it an attractive material.
The rocket was divided into three main areas: the booster, the avionics bay, and the nose cone. All three were constructed primarily out of the G-12 fiberglass. The booster’s primary functions are to transfer load from the motor to the rest of the rocket and ensure flight stability through rigid fins. It provides the backbone for the entire structure of the rocket; thus, great care was taken in its design and construction. CARM had four fins secured with centering rings running through the interior of the booster. The fins protruded through the fiberglass walls of the booster. This through-the-wall configuration was selected to maximize the rigidity of the fins. The fins were further reinforced with tip-to-tip fiberglass layups. The layups minimize the impact of bending moments, which could break the fins through fin-flutter or other aerodynamic stresses.
To secure the motor to the airframe, a custom thrust plate was designed. The thrust plate interfaced with our COTS motor mount and transferred the thrust from the motor into the body tube. The thrust plate was machined from a cylindrical block of aluminum.
The thrust plate had a ring of holes that connected with our COTS motor mount, slots cut out for fins, and grooves in the sidewall to help with epoxy adhesion. To manufacture this part, a solid cylindrical block of aluminum was placed on the lathe and the middle hole was bored out. In total, this part took approximately 10 hours to create, as there was a significant amount of material that needed to be removed.
The project culminated in a 32-hour road trip to Spaceport America, New Mexico, in which we battled 100°+ conditions with no AC. Once we got there, we still couldn't rest. Just one month earlier, during one of our test launches, the rocket landed in a tree, and we were unable to retrieve it. Consequently, we had to rebuild the entire rocket in a single month before the competition. We had gotten as much as we could done before the competition, but there was still much to be done to get it flight-ready. We converted our hotel room in New Mexico into a make-shift workshop and put the finishing touches on the rocket. We successfully launched on the last day to 9800 feet, placing 32nd overall. Overall, we were extremely pleased with this result and recognized that there was much to improve upon for the following year.