Team Members & Role:

 James Hornibrook: Team Lead

 Sean Belmonte: Design Lead

 Logan McGrath: Fabrication Lead

Jacob Roulier: 3D Printing Lead

Ethan Lynch: Analysis Lead

Brian St. John: Evaluation Lead

Abstract: The purpose of this project is to develop a 3D printed booster section for the UMass Rocket Team’s NASA USLI competition, to increase fin alignment and strength while reducing weight. The project’s goal is to ensure the booster section’s ability to withstand all forces encountered during launch and landing while improving predictability of flight metrics. Strength and precise fin alignment were identified as historical issues affecting the UMass Rocket Team’s performance, leading to structural failures and unpredictable flight characteristics. The project developed a fully 3D printed booster section, leveraging computer modeling for weight prediction accuracy and precise fin geometry. Recommendations included bolting the fins in place for easy replacement, a modified T-channel design for improved fin alignment, and removal of unnecessary material identified through Ansys analysis. The impact of the project’s contributions include enhanced launch vehicle integration, increased kinetic energy resilience, and rapid fin interchangeability for testing. The project adheres to NASA USLI and NFPA standards, emphasizing recoverability, reusability, and weight reduction. Each team member’s role, from design and analysis to fabrication and evaluation, contributed to the successful implementation of the 3D printed booster section. The project’s importance lies in its potential to prevent misalignment-related failures, offering a strong foundation for future iterations and tests.