Process Optimization and Structural Qualification of Carbon Fiber Rocket Components
Faculty Mentor
Awlad Hossain
Presentation Type
Poster
Start Date
4-14-2026 2:00 PM
End Date
4-14-2026 4:00 PM
Location
PUB NCR
Primary Discipline of Presentation
Mechanical Engineering and Technology
Abstract
This work presents the development, process optimization, and structural qualification of carbon fiber composite components for high-power rocketry. The Eastern Washington University Aerospace Club is preparing to compete in the International Rocket Engineering Competition (IREC) 2026 using these components. The vehicle is simulated to reach speeds up to Mach 2 and experience 28 G’s of acceleration. For the rocket airframe to survive these flight loads, high quality carbon fiber components need to be manufactured. Carbon fiber is lightweight, strong, and stiff, but difficult to manufacture. Pre-preg carbon fiber was selected to maximize stiffness-to-weight ratio while maintaining manufacturability within the club resource constraints, including the absence of an autoclave. The team developed an in-house, repeatable fabrication process for several different types of components. This process incorporated iterative layup refinement, curing optimization, fiber orientation consideration, and consolidation techniques to achieve a consistent structural profile. Mechanical and structural qualification testing was done via compression testing and ground-based tests using pyro charges. Test results verified that the fabricated components achieved the stiffness, strength, and mass efficiency required to withstand the predicted flight loads.
Recommended Citation
BUCHANAN, Collin; Silva, Zack; and Jump, Zach, "Process Optimization and Structural Qualification of Carbon Fiber Rocket Components" (2026). 2026 Symposium. 38.
https://dc.ewu.edu/srcw_2026/ps_2026/p3_2026/38
Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial-No Derivative Works 4.0 International License.
Process Optimization and Structural Qualification of Carbon Fiber Rocket Components
PUB NCR
This work presents the development, process optimization, and structural qualification of carbon fiber composite components for high-power rocketry. The Eastern Washington University Aerospace Club is preparing to compete in the International Rocket Engineering Competition (IREC) 2026 using these components. The vehicle is simulated to reach speeds up to Mach 2 and experience 28 G’s of acceleration. For the rocket airframe to survive these flight loads, high quality carbon fiber components need to be manufactured. Carbon fiber is lightweight, strong, and stiff, but difficult to manufacture. Pre-preg carbon fiber was selected to maximize stiffness-to-weight ratio while maintaining manufacturability within the club resource constraints, including the absence of an autoclave. The team developed an in-house, repeatable fabrication process for several different types of components. This process incorporated iterative layup refinement, curing optimization, fiber orientation consideration, and consolidation techniques to achieve a consistent structural profile. Mechanical and structural qualification testing was done via compression testing and ground-based tests using pyro charges. Test results verified that the fabricated components achieved the stiffness, strength, and mass efficiency required to withstand the predicted flight loads.
