Coach 30K
Spaceport America Cup 2022
Coach 30K was Duke AERO’s 2022-23 competition rocket, developed to fly at a maximum speed of Mach 1.8 on its way to 30,000 feet. Throughout the development of this rocket, a number of setbacks taught our team valuable lessons in persistence and dealing with failure. However, we still made it out to the competition in New Mexico and placed above the median. I was an active member of the Structures and Payload teams, participating in a number of mechanical and electronic build processes. Learn more about this rocket on the team’s website!
Spending time on Structures and Payload
The structures team is responsible for all parts of the rocket designed to handle the intense forces of flight. From composite tubes to machined parts, I spent time doing 3D design in OnShape and Solidworks to develop the structure of the rocket. Throughout the year, I participated in a number of wet layups for both carbon fiber and fiberglass composites. Additionally, I became familiar with our machine shop, using CNC mills, lathes, bandsaws, and more.
The 2022 payload was a muon detector placed in the nosecone of the rocket. The idea for this design came from Chris Knotek (seen above), and it incorporated several muon detectors stacked on top of each other separated by steel blocks. I machined and constructed a lot of the enclosure pictured above, while also working on much of the electronic infrastructure that made it function.
Dealing with Failure
After a full year of design and complete construction of the rocket, the unthinkable happened at our test flight: a tragic explosion only a few hundred feet off the ground. With only a few weeks left in the school year, a decision had to be made. Either frantically rebuild with exams imminent to make the competition, or call it quits. After several hard conversations, the team rallied together to commit to a full rebuild. Through several long days and nights, we were able to successfully manufacture the ruined components to be able to attend the Spaceport America Cup in 2022!