If you want improve a model rocket’s performance, all the common options come with serious trade-offs: you could increase the motor’s size, which raises safety issues, or you could cut down on weight, which limits the possible payload. [Con Hathy] was therefore intrigued by the design of the Arcas sounding rockets, which with the aid of a gas-fed launch tube could reach an altitude of 100 km. Even in models without a gas generator, a launch tube apparently boosted performance, an effect which [Con] was able to replicate in a much smaller model rocket.
In theory, as the rocket engine fires, it should pressurize the tube behind the rocket, providing an extra boost out of the tube. To test this, [Con] 3D printed a test rocket, launched it both from a standard rail and from a tube, and compared the results. During tube launches, a printed sabot fit around the rocket and formed a seal with the launch tube. The results were surprising: the tube-launched rocket actually performed substantially worse than a rail launch. After building a simulation, [Con] found that, as the rocket moves down the tube, the volume of tube it needs to back-fill with gas increases faster than the engine puts out exhaust; it was pulling a slight vacuum behind it, slowing itself down.
To solve this, [Con] decreased the diameter of the launch tube. To let the rocket fit into the tube, he also modified it to use pop-out stabilizer fins which wrap around the rocket while in the tube. The sabot was also shrunk, and had foam added to improve the seal between it and the rocket. For this second test, [Con] also connected a pressure sensor to the base of the launch tube. The results on the second launch were much better: according to an altimeter, it managed to fly 72% higher. Based on the pressure sensor’s data, a longer tube could have squeezed out still more performance, but this still demonstrated the principle quite well.
We’ve seen a tube-launched rocket before, though not with such a performance focus.
