Rocket-Powered Glider with Deployable Wing
Wing Designer | The Art of Engineering Course Project
Technologies & Tools
CAD & Analysis
SOLIDWORKS, Flow Simulation (CFD)
Manufacturing
Laser Cutting, Balsa/Plywood Construction
Design
Aerodynamic Optimization, Mechanical Integration
Problem: Vertical Launch, Horizontal Glide
Designed and manufactured a rocket-powered glider featuring a deployable wing mechanism for Columbia's introductory engineering laboratory course. The challenge required vertical rocket-powered ascent followed by controlled horizontal glide descent, necessitating a wing that could deploy mid-flight while maintaining aerodynamic efficiency and structural integrity.
As part of a 4-person team, I was responsible for complete wing design, aerodynamic analysis, manufacturing, and integration with the fuselage and deployment mechanism. The wing planform was modeled on the iconic Supermarine Spitfire's elliptical geometry, optimized for low-speed gliding performance.
Wing Design Specifications
Process: Design, Analysis & Iteration
Initial Wing Design
Planform Selection: Selected Supermarine Spitfire's elliptical wing planform for its aesthetically pleasing geometry and theoretically optimal lift distribution. Elliptical wings minimize induced drag by producing near-constant spanwise loading, though at the cost of increased manufacturing complexity compared to rectangular or tapered wings.
Aspect Ratio Trade-off: Designed with aspect ratio of ~3:1 to balance aerodynamic efficiency (higher AR preferred) against structural strength requirements and deployment mechanism constraints (lower AR preferred). The 30cm span provided adequate lift for controlled glide while maintaining compatibility with the sliding mechanism housing.
CFD Analysis: Learning Experience
CFD Limitations: Though the SOLIDWORKS Flow Simulation did not yield useful drag coefficient values due to simulation setup limitations and mesh resolution constraints, it was nonetheless valuable for visualizing how pressure distributes around the airframe and observing void formation (flow separation regions). This qualitative flow visualization informed design decisions regarding wing tip shaping and surface smoothness requirements.
Design Iteration: Nosecone Redesign
Problem Encountered: Excess Weight & Drag
Initial design exceeded weight budget and exhibited higher-than-acceptable drag during preliminary analysis. The rocket nosecone diameter was too large, contributing significant frontal area drag during boost phase.
Solution: Narrowed the rocket nosecone diameter to reduce frontal area and drag coefficient while also removing excess material to meet <100g weight specification. This design iteration improved both boost phase performance (higher altitude) and overall flight stability.
Before: Original wide nosecone
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After: Narrowed nosecone
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Wing Deployment Mechanism
Ejection Charge-Activated Deployment System
Mechanism Design: Wing deployment triggered by the rocket motor's ejection charge through a clever string-release mechanism. During boost phase, the wing remained in a streamlined stowed configuration, held in place by a restraining string under tension from a rubber band.
Deployment Sequence:
- Boost Phase: Wing held streamlined against fuselage by restraining string, rubber band tensioned and ready
- Apogee Detection: Rocket motor ejection charge fires at apogee (altitude peak)
- String Burn-Through: Ejection charge heat burns through restraining string
- Wing Deployment: Released rubber band pulls wing outward into glide configuration via sliding mechanism
- Glide Phase: Deployed wing provides lift for controlled descent
Integration Challenge: Wing mounting points had to align precisely with sliding mechanism rails while allowing smooth deployment motion. Collaborated with fuselage team member to ensure proper clearances and minimize binding during deployment.
Manufacturing Process
Laser Cutting: Manufactured wing components using precision laser cutter, enabling accurate reproduction of the elliptical planform geometry. Laser cutting provided clean edges and consistent dimensions critical for aerodynamic performance and assembly fit.
Material Selection: Used lightweight balsa wood for wing ribs and thin plywood for wing skins, selected for favorable strength-to-weight ratio and compatibility with laser cutting. Material thickness optimized for structural requirements while minimizing weight penalty to meet <100g specification.
Assembly Techniques: Assembled wing structure using wood glue and pinning, ensuring proper alignment of ribs, spars, and skin. Applied lightweight covering material for aerodynamic surface smoothness while adding minimal weight.
Manufacturing Photos: Laser cutting, assembly process
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My Contributions
- Designed complete wing geometry modeled on Supermarine Spitfire elliptical planform (30cm span, 10cm chord)
- Conducted SOLIDWORKS Flow Simulation CFD analysis for qualitative flow visualization and pressure distribution understanding
- Created engineering drawings with proper dimensioning for laser cutter manufacturing
- Manufactured wing components using precision laser cutter for accurate geometry reproduction
- Assembled wing structure from balsa ribs and plywood skins using wood glue and pinning techniques
- Collaborated with 3-person team to integrate wing with fuselage, sliding deployment mechanism, and propulsion system
- Contributed to nosecone redesign iteration, narrowing diameter to reduce weight and drag
- Performed ground testing of deployment mechanism and structural integrity validation
- Participated in successful flight demonstration achieving 60ft altitude and 7-second controlled glide
Solution: Flight Demonstration Results
Launch Configuration: Wing positioned in streamlined configuration during boost phase to minimize drag and maximize altitude. Rocket motor provided thrust for vertical ascent to deployment altitude.
Wing Deployment: At apogee (~60 feet), ejection charge activated, burning through restraining string. Rubber band successfully pulled wing into glide configuration via sliding mechanism. Deployment occurred smoothly without tumbling or loss of control.
Glide Performance: Deployed glider demonstrated stable, controlled descent with gentle glide pattern. Achieved approximately 7-second glide duration from 60-foot altitude, validating wing design and deployment mechanism effectiveness.
Flight Video & Photos: Launch, deployment, glide sequences
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Team Integration
Worked collaboratively with three team members, each responsible for different subsystems:
- Wing Design (My Role): Aerodynamic geometry, CFD analysis, manufacturing, assembly
- Fuselage: Body tube structure, nosecone design, center of gravity management
- Sliding Mechanism: Deployment rail system, rubber band tensioning, string restraint
- Propulsion System: Rocket motor selection, ejection charge timing, thrust alignment
Regular team meetings ensured component compatibility and coordinated assembly sequence. Resolved interface challenges including wing-to-rail alignment tolerances and center of gravity placement for stable flight.
Project Outcome: A+ Grade
Our team's rocket-powered glider project earned an A+ grade, reflecting the quality of our engineering analysis, manufacturing execution, and successful flight demonstration. The project demonstrated effective application of aerodynamics principles, CAD design, precision manufacturing, and systems integration in a collaborative team environment.
Course Context: The Art of Engineering is Columbia's introductory engineering laboratory course designed to provide hands-on experience with the engineering design process. The course emphasizes practical skills including CAD, manufacturing, analysis, and team collaboration through project-based learning.
Skills Developed
Technical Skills
- CFD analysis and flow visualization interpretation
- Wing planform design and geometry optimization
- Engineering drawing creation with proper dimensioning
- Laser cutting and precision manufacturing
- Lightweight structure design and construction
Project Management
- Collaborative team coordination
- Subsystem integration thinking
- Design iteration and problem-solving
- Testing and validation methodology
- Trade-off analysis (weight vs. strength vs. aerodynamics)
Key Takeaways
- Importance of weight management in aerospace design - every gram matters for altitude and flight duration
- Value of qualitative CFD analysis even when quantitative results are limited - flow visualization guides design decisions
- Critical role of manufacturing precision in achieving designed performance - laser cutting enabled accurate geometry reproduction
- Necessity of iterative design - nosecone redesign improved both weight and drag characteristics
- Systems integration requires careful interface coordination - wing deployment mechanism needed precise alignment with mounting points
- Satisfaction of seeing theoretical design validated through successful flight demonstration
Foundation for Future Work
The experience gained in this introductory project provided a foundation for more advanced aerospace projects including the AIAA Design-Build-Fly competition and NASA Micro-G NExT challenge, where similar skills in aerodynamic analysis, CAD design, and precision manufacturing proved essential.