Key Points
- The aerospace solutions provided by Mascherpa were tested in the Orion project by Skyward Experimental Rocketry across electronics, lubricants, and composites.
- The connections of the electronic boards, subject to breakage and critical conditions, were stabilized with DOWSIL 744.
- Propellant flow control was improved by treating the valves with Molykote HP 300, validated through Cold Flow tests and actual ignition.
- Bonding between composites and aluminum required precision and strength, achieved with the epoxy system Araldite 4858.
- From analyzing critical issues to validation on the sounding rocket, Mascherpa aerospace solutions were applied directly under real operating conditions.
In the Orion sounding rocket project by Skyward Experimental Rocketry, every technical choice originated as a solution to a real problem.
This is not about isolated laboratory work, but about repeated tests, critical conditions , and components that must always function. From managing onboard electronics systems, to controlling propellant flow and structural construction in composite, every aerospace solution was tested under high-stress conditions.
In this context, Mascherpa supported the team by providing solutions for aerospace across three key areas, composites, electronics e lubricants, addressing critical issues that emerged directly during development and sounding rocket testing Orion.
Solutions for onboard electronics connections
Within Skyward Experimental Rocketry, the avionics department handles the design of all electronic systems for the sounding rocket, at both hardware and software levels.
The main problem that emerged during the project concerned connection reliability.
The systems consist of several electronic boards that must communicate continuously with each other. During test phases, cables are connected and disconnected many times. Even when handled carefully, this progressively leads to connection breakage.
Operating conditions make everything more complex. In fact, inside the engine bay, temperatures reach around -20°C, and humidity represents an additional critical factor for boards and connections.
Providing structure to connections without compromising the system
With the support of Mascherpa technicians, a specific solution was identified: the use of DOWSIL 744, an elastic silicone sealant.
Application of this product enabled direct intervention on the system’s weak point, increasing the rigidity of the connections and improving their integrity.
The result is greater connection stability, with guaranteed sealing even in the presence of low temperatures and humidity.
Propellant flow control to prevent test failure
In transitioning to development of a liquid propellant engine, the propulsion team at Skyward Experimental Rocketry faced an immediate critical issue.
During initial tests, a failure to open the valves regulating propellant flow caused severe consequences. The The engine would detonate or explode, damaging components and completely invalidating the test.
The root cause was identified in the behavior of the valves, which would jam during opening. From this understanding began work on analysis and testing to identify a solution.
From analysis to product selection
After a series of analyses on and previous tests, together with Mascherpa technicians, the most suitable product was identified: the grease Molykote HP 300, to be applied to the valves for facilitate their opening during the ignition sequence.
Validation in tests and real-world performance of Molykote HP 300
The first use occurred during the Cold Flow test campaign, in which the valves are actuated without igniting the propellant.
In this phase, it was possible to verify that the grease functioned correctly and that valve opening met the required timing for a liquid propellant engine.
After this initial validation, the system was taken to actual ignition testing.
Even in this phase, performance remained stable. The valves maintained controlled opening, allowing regular flow of the propellant and making the ignition process more consistent.
At the end of testing, inspection of the valves confirmed that the grease was still present and had continued to ensure controlled flow.
Composite structures and bonding, a challenge of precision and strength
In the Orion project, the sounding rocket was built almost entirely from composite, with connection flanges in aluminum.
This choice introduced new challenges, particularly related to bonding. To join such different components, it was necessary to maintain geometric precision and the ability to transmit structural loads.
The solution identified was a two-component epoxy resin system Araldite 4858, selected with support from Mascherpa technicians.
Key aspects that emerged during the project:
- the need to maintain a thin and uniform bond thickness;
- managing concentricity without using jigs;
- resistance to mechanical stress, especially during the most critical phases such as parachute deployment.
The composite resin system met these requirements also thanks to a 60-minute pot life, useful for proper positioning of components.
These solutions were applied to structural elements of the sounding rocket, subject to loads and vibrations.
An approach that starts from the problem and leads to validation
In the Orion project, every solution was introduced based on a concrete critical issue.
Connections that deteriorate over time, valves that cannot yes fail to open correctly, bonds that must ensure precision e resistance.
In all cases, the work started from problem analysis, proceeded through testing and validation, and concluded with solutions applied directly to the sounding rocket.
It is in this process that aerospace solutions cease to be theory and become reliable components under real conditions.
For more information on the aerospace solutions used in the production of the Orion sounding rocket and on Mascherpa solutions used in other partnerships with university institutions, visit our Mascherpa Next page or contact our experts.
