Prototype Component Upgrade

Engineering Context

Fit testing has revealed one rocket component that is difficult to assemble, weak, or unreliable.

What You Will Practice

• Translate test evidence into design changes
• Revise a parametric part
• Plan a fair comparison
• Document prototype improvement

What You Need

• Original component and CAD file
• Fusion 360
• 3D printer
• Calipers
• Test materials appropriate to the component
• Engineering notebook

Instructions

1. Select one component and define the specific problem using evidence.
2. Choose one measurable performance indicator such as insertion force, alignment error, mass, deflection, or assembly time.
3. Record baseline measurements for the original component.
4. Sketch two redesign options and select one.
5. Revise the CAD while preserving required interfaces.
6. Print the revised component with recorded settings.
7. Run the same test on the original and revised versions.
8. Decide whether the revision should be accepted, modified, or rejected.

Engineering Requirements

• Define one measurable improvement target
• Preserve all required interface dimensions
• Change only features connected to the identified problem
• Use the same test method for both versions
• Document print settings and revision

Constraints & Safety

• One component only unless approved
• Use classroom-approved materials and test loads
• Do not claim improvement without comparative evidence

What You Submit

• Problem statement and baseline data
• Two concept sketches
• Revised CAD and STL
• Original/revised photographs
• Comparison data
• Revision decision and justification

Reflection Questions

1. Did the redesign meet the target?
2. What unintended effect appeared?
3. Was the test sensitive enough to show a difference?
4. What would be changed in Revision B?