Table of Contents
Thrust Vector Controlled Model Rocket (May 2022 - Present)
This project was started with the intention of undertaking the significant challenge of applying all the knowledge and skills I have acquired over the past few years to practical use. Here are CAD models of the main 3 iterations.
TVC Rocket V1
TVC Rocket V2
TVC Rocket V3
TVC System V1/V1.5
TVC System V2
The rocket involves the use of CAD, 3D printing, custom schematics/PCB designs, custom flight firmware/software, as well as extensive testing and simulation.
Early concept testing of breadboard flight computer. Teensy 4.0 based featuring a TVC system and reaction control wheel.
TVC Rocket V1 before assembly.
TVC Rocket V1 wooden dowel "skeleton."
TVC Rocket V1 next to chute and Av bay.
TVC System V1 after static fire test 1.
The motor mount hole was a bad idea :(
TVC Rocket V1 was retired due to being overly complex and overweight.
Original TVC Rocket V2 right before assembly.
Original TVC V2 mass moment of inertia measurement.
TVC Rocket V1 next to V2
TVC V1, V1.5, & V3
TVC V1, V1.5, & V3
TVC V1, V1.5, & V3(Top View)
TVC System V2 with 4mm ball bearings.
TVC Rocket V2 chute deplyment test from 200 ft AGL
TVC Rocket V2 with new nose and TVC shell before static fire 3.
TVC Rocket V2 failed the chute deployment test due to slow code response and chute bay jam(Dropped by Heavy Lift Y6).
TVC Rocket V2 after failed chute deployment test.
All flight computer development iterations within the last year(Front).
All flight computer development iterations within the last year(Back).
Currently, a stable revision of the flight computer is being assembled and the software is undergoing development for this vehicle. The subsequent steps involve measuring the vehicle's current properties in order to create a simulation to find PID values for the control system.
Scratch built High Power Rocket(Nov 2022 - Jun 2023)
This was a side project I designed and built to verify the performance of Flight Computer ONE V2 and to attain my level 1 high power rocketry certification. There were a total of two different designs, Here are their CAD models.
The first intended to use dual deployment, relying on the computer to fire pyro charges for vehicle recovery. I later decided against this due to the fact that the computer and code were new and untested. The first flight with prototype three failed due to motor CATO but the second flight was a success and resulted in certification!
It should also be noted that on the first flight, Flight Computer ONE V2 could accurately log data and detect various flight states the vehicle passed through, including an unusually fast descent. Also, on flight two the Mahony filter failed to provide accurate orientation after powered accent due to the loss of gravity vector.
Flight Computer ONE V2.0/V2.5 (Aug 2022 - Jun 2023)
Flight Computer ONE V2 was specifically designed and built to achieve high precision data logging and flight control in model rocketry applications. 3D models of version 2.0 and 2.5 are pictured below.
Version 2.0 of the board boasts four MEMS sensors, flash/SD memory, and two STM32F4 MCUs featuring seven PWM outs, four high current pyro channels with continuity sensing, two USART interfaces, I2C, and SPI ports. Version 2.5 removes the Co-MCU, adds 2 additional MEMS sensors, and a larger 3.3V LDO with a fixed input voltage. Both versions feature full integration of all components, eliminating the need for any breakout boards. The main and carrier boards are also constructed as a detachable mezzanine structure, enabling simple and cost effective hardware upgrades/tailoring in the future!
As of Fall 2023, Version 2.0 of the board has operated successfully all two high power rocket flights experienced. This is despite the fact that there was an overheating LDO regulator and a poor connection between the two boards. The PCBs for version 2.5 have arrived and will be assembled soon!
Flight Computer ONE V1 (May 2022 - Jul 2022)
Flight Computer ONE V1 was developed for the thrust vector controlled model rocket. It was my first major printed circuit board design incorporating a microcontroller. It is based around the Teensy 4.0 MCU and is comprised mostly of breakout boards. Here are some 2D PCB views.
The schematics and PCB were designed using EasyEDA, and the general nature of the components used was inspired by work from BPS Space, specifically AVA. I also referenced the design of other general purpose flight controllers.
The board is currently operational and has maintained its original functionality, however, I ran into issues with data logging, the large physical size, and the outdated MEMS sensors. This was the main drive to create versions 2.0 and 2.5.
Sub 250 Fixed-Wing UAV(Jan 2022 - Feb 2022)
This wing was designed with one major constraint in mind, it MUST be under 250 grams all up weight. With the increasing FAA regulation over UAVs, operating sub-250-gram vehicles allow for less restrictive operation. Here is a CAD model of my design.
I used eCalc's prop, performance, and cg calculators to theorize the aircraft's weight, balance, and performance information. I then used Fusion 360 to model the craft and configured Arduplane for the Diatone Mamba F405 MINI MK3.5 flight controller.
Packing tape laminated foam board cutout of final KF wing.
First second and third versions
eCalc(cg) wing span, aera, aspect ratio, cg, and cp infomation.
After two failed designs the third one performed as expected and most importantly was able to perform optimally at an all-up weight of only 238 grams! This is impressive as the aircraft is still capable of fully autonomous flight!
Heavy Lift Multirotor UAV(Jul 2021 - Feb 2022)
Pictured below is a near complete CAD model of my Y6 drone designed to lift heavy payloads while offering agility and reliability.
Final Y6 CAD model as of Summer 2023, nearly complete(missing GPS and VTX mounts)
The CAD model for this design was created in Fusion 360. Theoretical calculations were done in eCalc and the MCU runs a configured version of ArduCopter. Lots of soldering and wire management was necessary to put this all together. Reliability was added in the form of coaxial motors, dual GPS, and dual IMUs.
Attaching motor to arms and prepping ESC wires for soldering
Matek H743-WING V1 Flight Controller Prep
Ready for main assembly(this is also a packable form for travel)
ESC droOp
This project is nearly complete and prototype one is capable of fully autonomous flight with a 1.5 kg payload while retaining a thrust to weight ratio greater than or equal to 2! The next steps are to further tune the vehicle and create accessories like a servo gripper mechanism.
Thrust Vector Controled Coaxial Bicopter(Feb 2021 - Nov 2021)
This is a CAD model of my Thrust Vector Controlled Coaxial Bicopter. It was designed and built to learn more about thrust vector control, PID tuning, and autonomous flight.
This project required advance use of Fusion 360 to create and model the TVC system along with use of soldering and open source flight configuration software like INAV and Ardupilot.
Various hobby electronic parts used
Custom 2-axis gimbal used for inital PID tests
https://youtube.com/shorts/u69V69-ec3k?feature=share
Currently, the Bicopter is capable of stable manual flight in calm to moderate weather, efforts are somewhat underway to tune it for autonomous flight!
3D Printed Pendular Rudder Pedals (Aug 2020 - Jan 2021)
Here is my first major project! It's a set of nearly fully 3D Printed pendular rudder pedals. The goal of this design was to learn Fusion 360 and to provide a more accessible alternative to the only commercial option currently available.
This project was centered around improving my CAD skills whilst also improving my 3D Printing knowledge.
For such a big first project this turned out to be a huge success as it is still operational to this day and over 400 people have downloaded the files to make one for themselves! Files are available for download here: https://www.thingiverse.com/thing:4744321 and https://www.printables.com/model/54625-asare-pendular-rudder
