SLA 3D Printed Vortex Cooled Rocket Engine

December 8, 2020 by Danie Conradie 16 Comments

3D printing is an incredible tool for prototyping and development, but the properties of the materials can be a limiting factor for functional parts. [Sam Rogers] and colleagues at [AX Technologies] have been testing and developing a small liquid-fueled rocket engine and successfully used vortex cooling to protect a resin 3D printed combustion chamber. (Video, embedded below.)

Vortex cooling works by injecting oxygen into the combustion chamber tangentially, just inside the nozzle of the engine, which creates a cooling, swirling vortex boundary layer along the chamber wall. The oxygen moves to the front end of the combustion chamber where it mixes with the fuel and ignites in the center. This does not protect the nozzle itself, which only lasts a few seconds before becoming unusable. However, thanks to the modular design of the test engine, only the small nozzle section had to be reprinted for every test. While this part could be manufactured using a metal 3D printer, the costs are still very high, especially at this experimental stage. The clear resin parts also allow the combustion observed and more accurate conclusions to be drawn from every test.

This engine intended to be used as a torch igniter for a much larger rocket engine. Fuel is injected into the front of the combustion chamber, where a spark plug is located to ignite the oxygen-fuel mixture. The flow of the oxygen and fuel is controlled by two servo-operated valves connected to a microcontroller, which is mounted with the engine on linear rails. This allows the test engine to move freely, and push against a load cell to measure thrust. The spark is created before the valves are opened to prevent a delayed ignition, which can blow up the engine, and getting the valve sequence and timing correct is critical. Many iterations and destroyed parts later, the [AX Technologies] team achieved successful ignition, with a clear supersonic Mach diamond pattern in the exhaust.

This is just one more example of 3D printing and cheap electronics allowing impressive progress on a limited budget. Another example is [Joe Barnard]’s progress in getting a model rocket to land itself with a solid fuel engine. Companies and organisations have been using 3D printed components in rocket engines for a few years now, and we’ve even seen an open source version.

Robust Water-Rocket Launcher Gets The Engineering Just Right

November 5, 2020 by Dan Maloney 7 Comments

Normally when we run across a project that claims to be overengineered, we admit that we get a little excited. Such projects always hold the potential for entertainingly over-the-top designs, materials, and methods. In this case, though, we’ll respectfully disagree with [Zach Hipps] assessment of his remote-controlled soda bottle rocket launcher as “overengineered”. To us, it seems just right.

That’s not to take away from anything accomplished with this build. Indeed, we’re mighty impressed by the completeness of the build, which was intended to create a station for charging and launching air-powered water rockets. The process started with a prototype, built mainly from 3D-printed parts but with a fair selection of workshop scraps to hold it together. This allowed [Zach] to test the geometry of the parts, operation of the mechanism, and how it interfaced with the flange on the necks of 2-liter soda bottles.

Honestly, the prototype was pretty good by itself and is probably where many of us would have stopped, but [Zach] kept going. He turned most of the printed parts into machined aluminum and Delrin, making for a very robust pneumatically operated stand. We’ve got to say the force with which the jaws close around the bottle flange is a bit scary — looks like it could easily clip off a wayward finger. But if he manages to avoid that fate, such a hearty rig should keep [Zach] flying for a long time. Perhaps it could even launch a two-stage water rocket?

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Rocket Plane Build Aims For High Speed Flight

September 27, 2020 by Zoe Skyforest 19 Comments

[James Whomsley] likes flying, and likes flying fast. After reaching a speed of 114 miles an hour with an RC plane, he wanted to go further and break that record. To do so, he looked towards rocket power, and started a new build.

The design consists of a combination of 3D printed parts, laser-cut plywood bulkheads, and foamboard flight surfaces, with a few carbon fiber stiffeners thrown in here and there. For this early prototype, power is solely from hobby rocket motors, providing thrust for 1.6 seconds, meaning flight times are necessarily short. The craft is launched from an aluminium profile rail thanks to a 3D printed sliding guide pin.

Initial tests with two rocket motors were promising, leading to a second trial with a full six motors fitted. The thrust line was a little low, however, and a major pitch-up just after launch meant the plane only reached around 62 miles an hour. [James] still has a ways to go to beat his previous record, so intends to explore adding ducted fan propulsion to get the plane in the air before using the rockets as a speed booster in steady flight.

Of course, if you can’t lay your hands on rocket engines, you could always consider spinning up your own. (Or ditch the engine entirely.) Video after the break.

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Blow Dryers And Metal Shears: Hacks Of Early Falcon 9 Flights

June 13, 2020 by Roger Cheng 10 Comments

Orbiting over our heads right now are two human beings who flew to the International Space Station in a SpaceX Crew Dragon vehicle on top of a Falcon 9. The majority of coverage focused on the years since human spaceflight last launched from Florida, but [Eric Berger] at Ars Technica reminds us it also makes for a grand ten-year celebration of the SpaceX workhorse rocket by sharing some stories from its early days.

Falcon 9 is a huge presence in the global space launch industry today, but ten years ago the future of a young aerospace company was far from certain. The recent uneventful launch is the result of many lessons learned in those ad-hoc days. Some early Falcon 9 flights were successful because the team decided some very unconventional hacks were worth the risk that paid off. A bit of water intrusion? Dry it out with a blow dryer and seal it back up. Small tear in a rocket nozzle? Send in someone to trim a few inches with shears (while the rocket was standing vertical on the launchpad).

Industry veterans appalled at “a cowboy attitude” pounced on every SpaceX failure with “I told you so.” But the disregard for convention is intentional, documented in many places like this old Wired piece from 2012. Existing enshrined aerospace conventions meant the “how” was preserved but the “why” was reduced to “we’ve always done it this way” rarely re-evaluated in light of advancements. Plus the risk-averse industry preferred staying with flight-proven designs, setting up a Catch-22 blocking innovation. SpaceX decided to go a different way, rapidly evolving the Falcon 9 and launching at a high cadence. Learning from all the failures along the way gave them their own set of “why” to back up their “how” growing far beyond blow dryers and metal shears. We’re happy to see the fail-learn-improve cycle at the heart of so many hacker projects have proven effective to send two astronauts to the space station and likely beyond.

[Photo: SpaceX Crew Demo-2 on the launch pad]

Hackaday Links: April 19, 2020

April 19, 2020 by Dan Maloney 29 Comments

While the COVID-19 pandemic at least seems to be on a downward track, the dystopian aspects of the response to the disease appear to be on the rise. As if there weren’t enough busybodies and bluenoses shaming their neighbors for real or imagined quarantine violations on social media, now we have the rise of social-distancing enforcement drones. These have been in use in hot zones around the world, of course, but have only recently arrived in the US. From New Jersey to Florida, drones are buzzing about in search of people not cowering in fear in their homes and blaring messages about how they face fines and arrest for seeking a little fresh air and sunshine. We’re all in favor of minimizing contact with potentially infected people, but it seems like these methods might be taking things a bit too far.

If you somehow find yourself with some spare time and want to increase your knowledge, or at least expand your virtual library, Springer Publishing has some exciting news for you. The journal and textbook publisher has made over 400 ebook titles available for free download. We had a quick scan over the list, and while the books run the gamut from social sciences to astrophysics, there are plenty of titles that are right in the wheelhouse of most Hackaday readers. There are books on power electronics, semiconductor physics, and artificial intelligence, as well as tons more. They all seem to be recent titles, so the information isn’t likely to be too dated. Give the list a once-over and happy downloading.

Out of all the people on this planet, the three with the least chance of being infected with SARS-CoV-2 blasted off from Kazakhstan this week on Soyuz MS-16 to meet up with the ISS. The long-quarantined crew of Anatoly Ivanishin, Ivan Vagner, and Chris Cassidy swapped places with the Expedition 62 crew, who returned to Earth safely in the Soyuz MS-15 vehicle. It’s a strange new world they return to, and we wish them and their ISS colleagues all the best. What struck us most about this mission, though, was some apparently surreptitiously obtained footage of the launch from a remarkably dangerous position. We saw some analysis of the footage, and based on the sound delay the camera was perhaps as close as 150 meters to the launchpad. It’s hard to say if the astronauts or the camera operator was braver.

And finally, because neatness counts, we got this great tip on making your breadboard jumpers perfectly straight. There’s something satisfying about breadboard circuits where the jumpers are straight and exactly the length the need to be, and John Martin’s method is so simple you can’t help but use it. He just rolls the stripped jumpers between his bench and something flat; he uses a Post-it note pad but just about anything will do. The result is satisfyingly straight jumpers, ready to be bent and inserted. We bet this method could be modified to work with the stiffer wire normally used in circuit sculptures like those of Mohit Bhoite; he went into some depth about his methods during his Supercon talk last year, and it’s worth watching if you haven’t seen it yet.

3D Printed Swirl Rocket Injector Turns Up The Heat

March 11, 2020 by Tom Nardi 14 Comments

Conceptually speaking, a liquid propellant rocket engine is actually a very simple piece of hardware. All you need to do is spray your fuel and oxidizer into the combustion chamber at the proper ratio, add a spark, and with a carefully designed nozzle you’re off to the races. Or the Moon, as the case may be. It’s just that doing it in the real-world and keeping the whole thing from exploding for long enough to do some useful work is another story entirely.

Taking the process one step at a time, [Luke Walters] has been working on a 3D printed injector that tackles the first half of the problem. After nearly a dozen different prototypes, he’s come up with a printable injector design that atomizes the fuel and combines it with pressurized air at a suitable ratio for combustion. As you can see in the video at the break, it’s certainly capable of generating some impressive fireballs.

A cloud of highly atomized alcohol from the injector.

The internal passages of the injector have been designed in such a way that fuel (91% isopropyl alcohol) and air are spinning in opposite directions when they meet. This promotes more complete mixing, which in turn leads to a more efficient burn. Originally developed in the 1930s, so-called “swirl injectors” of this type were one of the key technological advancements made by Germany’s V-2 rocket program. Some ideas never go out of style.

Since the injector only touches the fuel and air prior to ignition, it doesn’t need to be particularly heat resistant. To be on the safe side [Luke] has printed the part in PETG at 100% infill, but in reality the flame front is far enough away that temperature isn’t much of a concern. That said, he does hope to eventually fit these injectors into some kind of combustion chamber, which is where things will start getting toasty.

To be clear this is not a rocket engine, and it produces no appreciable thrust. Turning a big flame into a useful means of propulsion is where things get tricky, almost as though it’s rocket science or something. But that doesn’t mean it can’t be done by suitably ambitious hackers.

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Hackaday Links: March 1, 2020

March 1, 2020 by Dan Maloney 16 Comments

Talk about buried treasure: archeologists in Germany have – literally – unearthed a pristine Soviet spy radio, buried for decades outside of Cologne. While searching for artifacts from a Roman empire settlement, the archeologists found a pit containing the Soviet R-394KM transceiver, built in 1987 and apparently buried shortly thereafter without ever being used. It was found close to a path in the woods and not far from several sites of interest to Cold War-era spies. Curiously, the controls on the radio are labeled not in Cyrillic characters, but in the Latin alphabet, suggesting the radio was to be used by a native German speaker. The area in which it was found is destined to be an open-cast lignite mine, which makes us think that other Cold War artifacts may have fallen victim to the gore-covered blades of Bagger 288.

Good news for Betelgeuse fans, bad news for aficionados of cataclysmic cosmic explosions: it looks like the red giant in Orion isn’t going to explode anytime soon. Betelgeuse has been dimming steadily and rapidly since October of 2019; as a variable star such behavior is expected, but the magnitude of its decline was seen by some astronomers as a sign that the star was reaching the point in its evolution where it would go supernova. Alas, Betelgeuse started to brighten again right on schedule, suggesting that the star is not quite ready to give up the ghost. We’d have loved to witness a star so bright it rivals the full moon, but given the times we live in, perhaps it’s best not to have such a harbinger of doom appear.

If you plan to be in the Seattle area as the winter turns to spring, you might want to check out the Vintage Computer Fair Pacific Northwest. We visited back during the show’s first year and had a good time, and the Living Computers: Museum + Labs, where the event is held, is not to be missed. The Museum of Flight is supposed to be excellent as well, and not far away.

Mozilla announced this week that Firefox would turn on DNS over HTTPS (DoH) by default in the United States. DoH encrypts the DNS requests that are needed to translate a domain name to an IP address, which normally travel in clear text and are therefore easily observed. Easily readable DNS transactions are also key to content blockers, which has raised the hackles of regulators and legislators over the plan, who are singing the usual “think of the children” song. That DoH would make user data collection and ad-tracking harder probably has nothing to do with their protests.

And finally, sad news from California as daredevil and amateur rocketeer “Mad” Mike Hughes has been killed in a crash of his homemade rocket. The steam-powered rocket was to be a follow-up to an earlier, mostly successful flight to about 1,900 feet (580 m), and supposed to reach about 5,000 feet (1.5 km) at apogee. But in an eerily similar repeat of the mishap that nearly killed Evel Knievel during his Snake River Canyon jump in 1974, Mike’s parachute deployed almost as soon as his rocket left the launch rails. The chute introduced considerable drag before being torn off the rocket by the exhaust plume. The rocket continued in a ballistic arc to a considerable altitude, but without a chute Mike’s fate was sealed. Search for the video at your own peril, as it’s pretty disturbing. We never appreciated Mike’s self-professed Flat Earth views, but we did like his style. We suppose, though, that such an ending was more likely than not.