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ASU Satellite Laboratory

Fuselage Design

Presenter: Eric Chen

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Fuselage Overview• Fuselage Design

– Lessons Learned• Aerodynamics• Wing Attachment• Electronics

– Thermal Design• Construction• Fabrication

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Fuselage Design• Design Objectives

• Housing Electronics– Easy access to electronics– Size and Shape

• Low Drag• Minimal Weight• Structural Support for Wing

– Cut-out section on top of fuselage– Attachment of Wing

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Fuselage Design• Past Lessons Learned

– Fuselage must resist impact from landing• Previous launches have broken electrical

components- Temperature Considerations

– Operation Ranges of the Electronics

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Aerodynamics• Design for Low Drag

– Long slender body - reduced form drag– Nose Cone – gradual increase in diameter

• Design for Stability– Wing set into the top of the Fuselage to help roll stability

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Fuselage – Wing Attachment• Aluminum Rib Structure

– Pros• Structurally Sound• Mounting Platform for Wings

– Cons• Difficult to Fabricate• Heavier• Takes up room in fuselage

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Fuselage – Housing Electronics

• Foam core to hold electronics in place• Accessibility of electronics through the

opening in the fuselage• Placement of electronics with respect to

position of center of gravity

Camera

RadioBattery Board

GPS

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Fuselage – Housing Electronics

• Center of Gravity Placement– Lateral– Longitudinal– Moving the electronic

components to manipulate C.G.

– Wing Placement will also effect C.G.

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Electronics – Thermal Placement

• Most of the electronics will not work below 273.15 K

• Temperature @ 30,000 ft = 231.24 K• Place Electronics to maximize thermal

output– Radio and Battery pack produce a lot of heat– Place these by Motherboard and Camera to

keep them warm• Use Foam to help Insulate

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Fuselage Construction

• Design Material– Medium Dense Fiberboard - (MDF)

• Male mold of Fuselage Design– Molding Mediums

• Plastic Vacuum Molding

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Fuselage Construction

• Why male Molds?– Consistent Reproducibility– Very Smooth External Surfaces– Two halves are easy to join and allow for

access to electronics– Allows for the placement of joining points

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Fuselage - Fabrication

• Lay Fiberglass/Carbon Composite on molds

• Use Vacuum Bagging• Strengthens Fiber/Epoxy Matrix by

eliminating air bubbles

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Overview• Fuselage Design will optimize:

– Aerodynamic Performance• Minimize Drag

– Electronics Housing• Thermal Design

– Structural Integrity • Wing Attachment• Impact Resistant• Minimize Weight