Responsible Engineer for the Aeon R test stand feedlines, designing for cryogenic environments, pressurized fluids, and thermal and dynamic loads. Incorporated DFM and developed risk mitigation skills to create back up configurations.
Fuel and Oxidizer Feedlines
As the responsible engineer for the test stand fuel and oxidizer feedlines, I collaborated with manufacturing engineers, weld technicians, and test engineers to deliver the system within a 2 month timeline. The feedlines included multi-ply double-braided bellows, powder bed fusion 3D-printed components, machined flanges, spring-energized metal seals, and v-band clamps. I designed custom hydrostatic proof plates and Orbital Tube Welding (OTW) weld fixtures, and analyzed the feedlines for potential risks and failures. Following the analysis, I validated a backup set of feedlines to save $30,544 per set of feedlines.
Throughout the internship, I designed 39 unique parts, released 21 components and assemblies, and pushed the feedlines 2 weeks ahead of schedule.
In-House V-Band Design
On a tight 1-month timeline, I designed, analyzed, and manufactured in-house v-band clamps connecting the turbopump inlets to the feedlines based on gapping requirements and yield strength. I worked with manufacturing engineers and machinists to receive feedback on designing for manufacturing to deliver this component for engine testing as a backup option for the COTS v-band clamps. I also developed a more accurate method to analyze v-band joints to better model how the torque on the t-bolt translates into the sheet metal bands providing a uniform clamping force.