Embracing Failure and Pursuing Continuous Improvement

You might be wondering what the Michigan Aeronautical Science Association - Dearborn has been up to, especially since you’ve been following my posts and know how passionate I am about this club, which I consider my family. Today, I want to share my experience of going to a competition for the third time, and yes, I have an inspirational and touching story for you. As I was packing my bag, excited to go to New Mexico and finally fly our rocket at the Spaceport America Cup, the world's largest rocketry competition, I reflected on our journey. Our team of 40 dedicated and passionate engineers worked tirelessly for an entire year, from design to achieving apogee, building not just a rocket but also strong relationships and connections along the way. Driving the 26 hours from Michigan to New Mexico was quite an adventure, and upon arriving, we were closer than ever to launch day.

On the morning of June 19th, 2024, everything was going perfectly. Integration steps were being followed meticulously with my integration checklist, and everyone was bonding and nervous to see PROJECT S.H.A.G.E.E. in action. On the technical side, our target apogee was 30,000 feet, and this is the exact motor we used:

• Cesaroni N5800

• Burn Time: 3.60 sec

• Total Impulse: 20,368 Ns

• Average Thrust: 5767 N

• Max Thrust: 6957 N

• Launch Mass: 32.7 lbs

• Case Mass: 11.9 lbs

• Case: Pro98-6GXL
  

Our rocket was a single-stage design, equipped with an airbrake, payload, and an avionics bay. Here is a detailed diagram of our rocket: 

After the integration process was completed, it was time to move on to the launch pad. We all waited in the car as the temperature soared above 100°F. Everything seemed ready to go, and we did our final check-in before driving towards the launch pad. Now, I'd like to introduce Perla Fares, our Project Manager, who will share her insights and experiences on how everything came together and what happened next. 

“As we arrived at the launch pad area, we quickly gathered our rocket and tools—ladders, checklists, face shields, and more—and headed to our chosen spot. The atmosphere was electric as the team moved in perfect harmony, checking off our lists, sliding the rocket down the rail, and adjusting it to the perfect angle. Everything was running so smoothly, it felt almost surreal. When Project S.H.A.G.E.E. stood tall and proud on the rail, we all paused, our breath catching in our throats. In that moment, we forgot the countless hours of hard work and sacrifices that had brought us here.

Just as I began to walk back to the car, the walkie-talkie crackled to life, and I heard my name being called urgently. The news hit me like a punch to the gut—some team members had become dehydrated and were taken to the medical tent. In an instant, the triumph of the moment faded. I forgot about the rocket and sprinted to the car, my heart pounding as I rushed to the medical tent to check on our team members.” -Perla Fares

As all of this was happening, part of the team rushed to the bleachers, eager to finally watch the launch. Meanwhile, Perla was back in the medical tent, tending to our dehydrated members. Perla moved from one person to the next, offering words of encouragement and ensuring everyone was stable.It was a tense moment, balancing the excitement of the launch with the concern for our team’s well-being. But amidst the chaos, the countdown began. It was there, finally the right time… It is time to fly after all… 3…2…1…

And then, we saw it—our rocket took off in a spectacular blast. The initial moments of flight were exhilarating, but then a blip occurred. Our hearts sank as we watched the nose cone detach mid-flight, causing the rocket to lose stability. At that point, we knew something was wrong, but what? What had happened? Tears welled up in my eyes as I thought about the year of hard work that led to this moment. Questions began to arise, and our team members were visibly disappointed. The culmination of our efforts had not gone as planned, leaving us all searching for answers.

After that long day, we held a team meeting and concluded that the only way to understand what happened with the rocket was to recover it. Despite having no data or idea of its location, we decided to go. Early the next morning, at 4 AM, Maksym, Caleb, Perla, and I drove back to the desert.

"My mind raced with questions as we walked through the desert for eight long hours. Finally, we received word that another team had found a piece of our rocket—the upper booster housing our avionics and payload. As we approached the location, we were disheartened to see everything burnt, with clear evidence of nosecone failure visible in the wreckage. Did something trigger prematurely? Was there a mechanical failure, or perhaps an issue with the design itself? These questions ignited a flurry of ideas for potential solutions and improvements in our engineering approach." - Maksym Rozhko

Three days after recovery, following a meticulous process of retracing our steps to locate the booster and other potential parts, we managed to recover our upper booster, nosecone, and a small coupler. This investigation provided us with a clearer understanding of what had transpired, especially as even our mentors were initially puzzled by the outcome. One thing we can confirm is that the motor we used was too powerful for our rocket, which led to the failure of the nosecone. This revelation opens up avenues for new research experiments aimed at learning how to reinforce our nosecone design.

Interestingly, during our recovery efforts, we observed another large collegiate rocket experiencing a similar issue with the N5800 motor, underscoring the broader relevance and potential for shared insights in our field.

"Even though our rocket didn't perform to our expectations, we were all very grateful for the experience and opportunities we were given. Over the last year, I can confidently say that being a part of this team has helped me grow both as an engineer and a person. I have obtained leadership and practical skills that I would not have gotten otherwise. Despite the setbacks, our perseverance and teamwork have been invaluable lessons, and I look forward to applying what we've learned to future projects." -Andrew Brown

And that is all the learning I have to share with you today.

GO BLUE! GO DEARBORN!

Best,

Bruna O. Rocha