As an airframe team member working on Caldera, our two-stage rocket for the IREC 2024 Spaceport America Cup, I’ve been deeply involved in every aspect of the rocket’s physical construction and preparation. My role has been both challenging and rewarding, requiring a blend of creative problem-solving, precision engineering, and hands-on craftsmanship.

One of my primary responsibilities was designing and creating camera mounts and aerodynamic shrouds for our Insta360 Go3 cameras. These components were crucial for capturing high-quality onboard video footage during flight. I went through multiple iterations of prototypes before finalizing designs that were both secure and aerodynamically efficient.

A significant part of my work involved developing manufacturing processes for the rocket’s construction. I modified a tile saw to make incredibly precise cuts on our fiberglass body tubes, ensuring each section was perfectly sized for assembly. This attention to detail was crucial for maintaining the rocket’s structural integrity and aerodynamic properties.

Integration of components was another key area of my work. I designed custom fillet tools using a laser cutter and created 3D-printed jigs to assist in the precise application of structural epoxy when attaching bulkheads and fins. This meticulous approach ensured that these critical components were securely and accurately bonded to the airframe.

To enhance the rocket’s durability, I reinforced high-stress areas like fin attachments and body tube joints. This involved carefully applying composite materials, cold-impregnating fiberglass cloth with epoxy resin to create strong, lightweight reinforcements.

The airbrake subsystem was particularly complex, and I spent considerable time fine-tuning and assembling this crucial component that helps control our rocket’s altitude. Getting this system to work flawlessly was essential for our competition performance.

My role extended beyond the workshop to the launch field. During test launches, I was responsible for integrating the full vehicle and assisting with safe recovery operations after each flight. These experiences were invaluable in identifying areas for improvement and ensuring our rocket was competition-ready.

Finally, I had the privilege of representing our team at the Spaceport America Cup. There, I helped with the final integration of Caldera and participated in recovery operations after our competition flights. It was incredibly rewarding to see our hard work put to the test against teams from around the world.

Throughout this project, I’ve gained invaluable hands-on experience in aerospace engineering, from design and prototyping to manufacturing and testing. Working on Caldera has not only enhanced my technical skills but also my ability to work as part of a high-performing team under the pressure of competition deadlines.