www.3ders.org

Nov 25, 2015 | By Kira

There’s something undeniably exciting about a rocket lift-off, whether it’s the countdown for a NASA spacecraft, or a small-scale bottle rocket. Offering a low-cost yet equally exhilarating DIY option, makers Jake Veilleux and Mark Fuller created a 6.5’ tall rocket with a 16” tall 3D printed nose cone that they were able to successfully launch roughly 1,200 feet (365 meters) into the air. Using little more than standard mailing tubes, plywood, a G40-7 rocket engine, and three 3D printed parts for the nose, the Layered Success rocket cost under $30 to make, and as the name implies, was quite the success.

According to Veilleux and Fuller, the initial design for the Layered Success rocket was conceived of about five years ago, but due to several moves, it could only be completed this summer. The rocket consists of standard 2” mailing tubes, which can be purchased from UPS or just about any post office, quarter-inch sanded plywood for the fins, which are held together with old fashioned Elmer’s wood glue, a G40-7 engine, which offers roughly nine pounds of thrust, and of course, the 3D printed nose cone.

Fuller used Solidworks to design the nose cone before 3D printing the first prototype on a Da Vinci 1.0 desktop 3D printer. After a few redesigns, he was able to 3D print the finished model. Since most 3D printers offer around 8 inches in vertical height, he chose to 3D print it in three separate parts (currently available to download on Thingiverse), which once assembled, measure up to 16 glorious inches. They were 3D printed with no supports at 2mm thick. He then solvent-welded each piece together using a mix of ABS and acetone.

Since the finished product was far from skyrocket smoothness, Fuller applied more of the ‘ABS juice’ (the acetone and ABS mix) to the surface, and then smoothed out the remaining pits with 80-250 grit sandpaper.

According to the makers, they were able to reduce overall costs by using a standard 6’2” mailing tube and 3D print around those measurements, rather than buying a dedicated rocket tube and then having to spend another $30 for a pre-made nose cone. “The total cost for this rocket was $5 for wood and $20 for the rocket bring the entry into flight way down compared to $120 kits,” said Fuller, adding that the Da Vinci 1.0 3D printer is itself only around $500. “Solvent welding the surface increased the over all strength of the part fusing the plastic together and it had no problem on its 1,200 Feet Trip.”

Veilleux and Fuller brought their finished, 6.5’ (1.98 meter) tall rocket to a launching ground in Pooler, Georgia, a suburb of Savannah, and after five years of anticipation, finally got to see their rocket take flight.

Though the cell-phone video doesn’t exactly capture everything in detail, the rocket clearly soars high into the sky, and ends up landing 0.38 meters (0.6 km) away (the launch happens at approximately 7 minutes). Once recovered, the creators were able to confirm that the 3D printed nose cone was still perfectly intact, with no cracks or visible damage. As Fuller puts it, the Layered Success can now boast yet “another layer...of success.”

 

 

Posted in 3D Printing Application

 

 

Maybe you also like:

• In-Q-Tel, CIA’s venture-capital arm, invests in 3D electronics printing platform Voxel8
• 3D print an entire PCB test version to ensure it always fits
• Voovo launches budget 3D printing service platform where you can auction off print jobs
• NanoSteel expands material portfolio for metal 3D printing
• MIT project introduces modular machines for the rapid prototyping of rapid prototyping machines
• Ford uses 3D printing to help develop revolutionary new smart bikes
• Razer announces OSVR Hacker Dev Kit with 3D printable virtual reality headset
• GriTT 3D affordable, custom made 3D printed mouthguards launches on Indiegogo
• Hobbes the three-legged dog to get 3D printed prosthetic leg from California students

   

Leave a comment:

Your Name: