Propulsion

Overview

The Propulsion Department of Skyward develops and tests advanced rocket engines, specializing in hybrid and bipropellant (bi-liquid) propulsion systems. Our team handles the entire development cycle, from fuel formulation and combustion analysis to thermomechanical sizing and structural design. We also create in-house simulation codes that model engine performance, enabling us to validate and optimize our designs before testing. Whether working on ignition systems, cooling strategies, or thrust optimization, we approach each challenge with a practical and engineering-focused mindset, aiming to improve step by step through testing and experience.

Design

We conduct CFD simulations across a spectrum of boundary conditions that represent various flight parameters, including velocity, pressure, and altitude. We examine different flight scenarios, such as steady-state flows, and consider both compressible and incompressible regimes, as well as subsonic and supersonic speeds. Additionally, our team performs plume simulations to analyze the behavior of motor exhaust and its interaction with external airflow, essential for understanding the overall aerodynamic performance. Upon completing the simulations, we evaluate convergence and perform detailed post-processing to extract aerodynamic coefficients, pressure distributions, and flow visualizations.

Production

The production phase involves both internal manufacturing and collaboration with external partners. Critical components are machined or assembled in-house using our laboratory equipment, ensuring tight control over quality and integration. For more complex or high-precision parts, we rely on trusted industry partners who support us with their expertise and capabilities. Throughout the process, we maintain close coordination between design and production teams to ensure that each component meets the required specifications and is ready for integration and testing.

Testing

The testing phase starts with cold flow tests, which allow us to characterize fluid behavior and evaluate injector performance without combustion. These tests provide valuable data on pressure drops, flow rates, and spray patterns. Once the system is validated, we proceed with static fire tests, where the engine is fired to verify the design under real operating conditions. During these tests, we acquire thrust and chamber pressure curves, which are then shared with other Departments to simulate flight conditions and assess overall mission performance.

RPS

The team is responsible for the development of the hybrid flying engine, from a propulsive point of view. The team shall strictly cooperate with all the other Departments in order to be compliant with the proposed constraints. The team shall choose the dimensions of the propulsive system, evaluating the performances through an optimization process. Furthermore, it shall perform thermal analyses in order to assess the correct functioning of the engine subsystems.

LPS

The R&D team is currently focused on the development of a next-generation bipropellant rocket engine, a project that has been ongoing for the past two years. This engine integrates advanced design choices and is manufactured using both additive manufacturing and traditional production methods, allowing for greater flexibility in design and production. With the support of other departments, the team aims to validate this technology with the ultimate goal of developing a flight-ready engine.

Requirements

Base

  • A proactive approach to problem-solving
  • Basic knowledge of physics, thermodynamics and chemistry
  • Basic knowledge of a rocket engine
  • Interest in coding and software-aided thermal simulations
  • Basic knowledge of CAD
  • Strong team-work capabilities

Advanced

  • Good dexterity (experience in the use of tools and / or in the assembly and disassembly of components)
  • Knowledge of finite element analysis software (Abaqus and Ansys)
  • Experience in 3D printing
  • Knowledge of Matlab and CEA