Structural Design and Sizing

Every great rocket begins with a solid idea and solid structures. Our work starts by defining the constraints each component must withstand during flight: speed, pressure, vibrations, and more. From initial sketches to detailed 3D models, we shape every part using CAD software, in close collaboration with other departments to ensure that form and function go hand in hand.

Once the overall structure is defined, we move to optimization—where the real engineering challenge begins. Using Finite Element Analysis, we simulate the most extreme conditions the rocket might face and refine each piece by removing any excess material, keeping only what’s essential for strength and safety.

It’s a balance of precision, creativity, and purpose. Because behind every bolt and flange, there’s the drive to build something that can rise above the Earth—and the passion of a team turning ideas into flight.

Manufacturing and Assembly Integration

Design is just the beginning, bringing the rocket to life is where the real excitement starts. Once every component has been fully designed, we create the detailed technical drawings needed for production. Thanks to the support of our generous sponsors, many of the more complex parts are manufactured externally with high precision.

When the components arrive, it’s our turn to get hands-on. We carefully assemble each section of the rocket, often repeating the process multiple times to ensure every piece fits perfectly and performs its role. This stage is all about precision, teamwork, and attention to detail.

As the rocket nears completion, we begin the integration phase, working side by side with other departments to bring all systems together into one unified, flight-ready vehicle. It’s the moment where design meets reality—and where our vision finally starts to take shape.

Composite Tooling and Lamination Process

For components made of composite materials, we take full ownership of the process—from start to finish. Our team designs and manufactures the molds entirely in-house, tailoring each one to meet the specific geometry and structural needs of the rocket. Once the molds are ready, we move on to lamination, carefully layering carbon fiber and resin to create parts that are both incredibly strong and lightweight. This hands-on process demands precision, patience, and attention to detail—but it’s also one of the most rewarding, as we watch raw materials transform into high-performance aerospace structures, built by our own hands.

Subsystem Integration and Structural Verification

Even the most precise design needs to prove itself in the real world. That’s why, once the individual components are ready, we begin a careful process of integration and testing. Starting with the expulsion system, we verify that each part operates as expected and interfaces correctly with other key subsystems—such as avionics and the recovery mechanism.

This phase is all about making sure that every piece, no matter how small, works together seamlessly. And when everything checks out, we move to the final step: assembling the full rocket and mounting the launch rail. It’s the moment where months of work come together