1. Leslie Elwood Erik Nelson Jacob East Joe Shields Brandon Bonner
LV3 Capstone Project
Leslie Elwood
Erik Nelson
Jacob East
Joe Shields
Brandon Bonner

2. Mission Statement
Design and Fabricate 2 significantly lighter airframes using processes developed by the 2015 capstone team.

3. What we have: LV2 Aluminum and fiberglass (heavy) Small diameter
Simple geometry

4. What we need: LV3 Carbon fiber (light and strong) Large diameter
Aerodynamic
Well documented

5. Choose / Create a Nose Cone design based on the same parameters.
Deliverables (PDS)
*Must*
Research and Design
Choose / Create fin design based on stability, weight, flutter, and heating characteristics for Mach 3 and expected maximum dynamic pressure.
Choose / Create a Nose Cone design based on the same parameters.

6. Deliverables (PDS) *Must* Manufacture
Motor module, payload avionics module, Rail buttons and Fin Canister for 2 complete LV3 specified rockets.
All modules made from carbon fiber and co-molded with aluminum coupling rings

7. Deliverables (PDS) *Must* Testing Non-destructively test all pieces.
Destructively test one module
Documentation
Fully document design and manufacturing process. Create a handbook for manufacturing carbon fiber modules for future launch vehicles

8. Deliverables (PDS) *Should* Complete 3 of each module.
Complete CF nose cone.
Metal leading edges on fins.
Use lean methods to streamline manufacturing process of all components

9. Process Flow Research Design Procure Document
Analyze Launch 12 data to determine fluid regime.
Research nose cone shapes for given flow regime.
Fin designs for stabilization at given flow speed.
Design
Choose / Modify existing designs or create design for nose cone and fins.
Design needed tooling to create nose cone and fins / fin can.
Attachment method for fins to fin can.
Procure
Secure additional funding sources.
Determine material need.
Identify available products.
Solicit donations of materials.
Manufacture
Create tooling for nose cone and fins.
Machine additional coupling rings.
Make cylindrical modules.
Make fins.
Make nose cone.
Attach fins to fin canister.
Document
Create a manual that documents our process and passes on adequate knowledge to subsequent groups to recreate our process with minimal training.

10. Fin Design Complex Delta Tapered (custom) Tapered Half Hex
Tapered Half Chevron
Swept Back

11. Fin Design Design Elements Overall Shape Edge Profile and Material
Attachment Method to Canister
Possible Aluminum Structure
Design Factors
Fluid Drag
Flutter
Weight
Strength

12. Nose Cone Design

13. Nose Cone Design Design Elements Overall Shape Tooling
Manufacturing Process
Material
Design Factors
Fluid Drag
Mach Characteristics
RF Transparency?
Strength

14. Estimated Budget Material Qty Product Est. Cost 6061 T6 Aluminum
4 ft x 8” round bar
Coupling rings, nose cone mandrel ,Rail buttons?
$1400
Prepreg High Temp Cure Carbon Fiber
Est 60 yd
Nose cone, Fins, Airframe
$3500
3M epoxy film adhesive
Est. 60 yd
$1200
Curing Materials:
Shrink tape, Flash tape
Mold release agent, pretreatment chemicals
$1000-$1500
Est Total
$6200

15. Timeline Task Date Purchase / Acquire material 2/19
Machine coupling rings
3/4
First CF pieces fully cured
Fin frames machined
3/11
Nose cone mandrel machined
3/18
Airframe modules complete
4/1
Fins complete
3/25
Fin cans complete
4/15
Nose cone complete
4/29
Documentation complete
5/13

16. Conclusion portland State Aerospace Society: because space
needs more Vikings!