Objective: Developed an onboard video system for Northwestern's 2024-2025 NASA USLI launch vehicle.Â
Requirements: Capture stable, in-flight footage of the rocket and its control surfaces (active drag system) without compromising aerodynamics or internal payload layout. The system had to withstand launch forces, interface with avionics, and support field assembly.
Top Skills: mechanical design (OnShape CAD, BambuLab 3D printing), stress analysis (Ansys), systems integration, project management, technical writing
video will point downwards from the rocket nose cone like Starship's onboard footage
chose RunCam Split 4 V2 camera to minimize rocket surface protrusion by separating lens from module
reverse-airfoil shape chosen for external camera housing to reduce drag
secure camera and its electronics on nosecone using a heat-set inserts and screws in PCB mount to thread through all components
PDR Onboard Video Layout (Nosecone Interior View)
PDR Camera Housing Iteration
RunCam Split 4 V2
PDR PCB Mounting Board Iteration
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
CDR Construction Jig
OpenRocket Stability Analysis
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
Camera Housing and Dummy
Nosecone Internal Assembly
Switchband Assembly
Test Flight #1 Parachute Charge Issue
Camera Fit Testing
Drilling Hole With Jig Into Switchband
Closeup at Flight Test 1
Test Flight #1 Payload Antenna Issue
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
Test Flight #1 Active Drag System Validation
Circuit Board Mount
Camera Housing
Mount Subassembly
Final Assembly
The onboard video system successfully captured in-flight footage from within the rocket, validating the mechanical and electrical integration work done throughout the design process. However, the footage revealed noticeable roll-induced motion, making the video disorienting. This highlighted the need for improved roll stability control or post-processing stabilization in future flights. As a next step, installing a second outward-facing camera could provide a broader visual context for analyzing flight dynamics and control system performance.
I have had my fair share of month-long engineering projects, but this has been the most technically complex and rewarding. I gained a passion for aerospace engineering and became closer with the team through helping own this particular subsystem.