Rocket Onboard Video System

Objective: Developed an onboard video system for Northwestern's 2024-2025 NASA USLI launch vehicle. 

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

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

Key Takeaways

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.