Simplify the Rocket Assembly

Engineering Context

The current rocket assembly works, but technicians report too many parts, repeated fasteners, and slow assembly.

What You Will Practice

• Analyze assembly complexity
• Apply design for assembly principles
• Preserve interfaces and motion
• Compare original and revised assemblies

What You Need

• Existing rocket assembly CAD
• Fusion 360
• Bill of materials
• Stopwatch or assembly-time estimate sheet
• Engineering notebook

Instructions

1. Create a baseline BOM and count unique parts, total parts, fasteners, and assembly steps.
2. Identify three assembly pain points.
3. Generate two redesign concepts that combine parts, replace fasteners, improve alignment, or reduce orientation errors.
4. Use a decision matrix to select a redesign.
5. Modify the CAD assembly and update joints or constraints.
6. Create an updated BOM and assembly sequence.
7. Compare predicted assembly time and part count.
8. Check for new manufacturing, repair, or tolerance problems.

Engineering Requirements

• Reduce total part count or assembly steps by at least 20%
• Preserve rocket exterior envelope and required interfaces
• Maintain access to parts that may require replacement
• Use realistic manufacturing methods
• Update the assembly and BOM completely

Constraints & Safety

• No change may interfere with the provided rocket requirements
• Use only available manufacturing processes
• Do not hide separate components by merely grouping them in CAD

What You Submit

• Baseline BOM and sequence
• Three identified pain points
• Two concept sketches
• Decision matrix
• Revised assembly file
• Updated BOM
• Before/after comparison

Reflection Questions

1. Which assembly step created the greatest difficulty?
2. How did your redesign affect repairability?
3. What tolerance issue could appear in the combined part?
4. What physical test should verify the change?