We have developed a carbon-fibre composite rocket body and successfully tested it to launch requirements.
We designed and manufactured a Gridded Rocket Body, Payload Module utilising the superior performance of an ortho-grid structure. By using 0°/90° and ± 45° orientations we were able to test the characteristics of each and determine to most suitable approach. Gridded structures save weight and use minimal material.
The design is based on a single-stage REXUS rocket module which gives real-world application to this demonstrator. Thermoplastic unidirectional carbon fibre tapes were precisely placed with a customised robotic laser-assisted fibre placement system. These modules can be equipped with 3D printed housings with embedded electronics for telemetry and communication functionality.
Manufacturing Details:
Manufacturing Process: Robotic laser-assisted fibre placement with customised dual-laser placement head (AFPT GmbH)
Material: Continuous unidirectional high-strength AS4 CF/PEEK tape, 55% FVF, bonded Aluminium 6061-T6 rings
Dimensions: External diameter: 355.6 mm | Length: 300 mm |
Laminate thickness: 10 mm | Number of plies: 74
Manufacturing Time: 240 min / module
Embedded Electronics: L-Band antennae, customised 3D printed antennae on Tecglass, IoT Telemetry (GPS, CATm, LTE), Raspberry Pi. Available with customised embedded electronics, such as Raspberry Pi 4, fitted with Waveshare SIM7080G IoT transmitting hat (supports GNSS position tracking), demonstration patch antenna, printable on either 2D or 3D surface or similar.
The gridded composite sounding rocket interstage section successfully ran to the required qualification vibration level without damage. The interstage section, designed to interface with a Rexus sounding rocket, was tested to the NASA Sounding Rocket random input vibration profile with the duration increase from 10 to 50 seconds as specified by the DLR Mobile Rocket Base (Moraba). The vibration testing was conducted on the shaker at the National Space Testing Facility at Mt. Stromlo in Canberra.
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