NASA USLI Launch Vehicle Onboard Video System

October 2024 - January 2025: Critical Design Review (CDR)

• integrated camera with flight controller, allowing remote control over starting/stopping recording

• recording system operates independently from vehicle's telemetry, allowing continuous footage without relying on constant data link

• footage stored on microSD card within camera PCB

• tested various infill densities/orientations as well as materials (Nylon 12, ABS, PLA) to 3D print camera housing and camera PCB mount

• 4-40 brass heat-set inserts used to secure screws inserted through camera housing holes

• developing FMEA to incorporate redudancies

• comparing model of launch vehicle in OpenRocket with/without camera system yielded less than a 1.5 cal stability reduction

January 2025 - April 2025: Manufacturing & Flight Testing

• Ansys structure validation & CFD drag estimation

• two camera housings placed on rocket exterior for aerodynamic symmetry (only one with camera)

• assembling subsystem within nosecone and nosecone switchband

• hole drilled through the fiberglass switchband to allow wiring to pass through rocket interior/exterior

• wiring system to power and TeleMega flight computer

• successful Flight Test #1 with recorded video

April 2025 - May 2025: Flight Readiness Report (FRR) & NASA/Northrop Grumman Competition!

• validated successful active drag system actuation from Flight Test #1 video

• identified charge sizing issue in primary and backup drogue parachute charges, leading to increased primary charge to successfully deploy on first attempt in future flights

• identified cause of payload antenna failure to strengthen antenna holsters for future flights

• successful Flight Test #2

• camera died during Flight Test #3 assembly, leading to preparation measures taken to prevent power surges

• successful competition flight at Huntsville, AL

Final Design in OnShape