Engineering concept
Design hollow printed modules, physically removable connections, fin-locating slots and a separate grounded launcher reference in one Fusion assembly.
IED Unit 3 • Lesson 3.7
Rocket Component Design & CAD Assembly
Focus question: How can component geometry and assembly relationships be designed together so the physical rocket will actually fit and function?
Your lesson guide
Objective
Create each major rocket module as an identifiable Fusion component. Design removable printed-to-printed interfaces around intentional geometry. Model laser-cut fins at measured stock thickness.
Materials
For the online work: a browser and your engineering notebook. Follow the activity’s materials list for any physical build, and get teacher approval before using equipment.
Plan your time
Suggested work block: 45–60 minutes. Physical builds and projects may span several classes; follow your teacher’s schedule.
IED Unit 3 • Lesson 3.7 • Learning Studio
Learn the concepts before completing the assignment
Today's engineering work
Model lower launch/fin module, body and blunt nose separately; keep basic walls approximately 1.2–2.0 mm; create detachable couplers; add 3 or 4 separate fin components.
Worked example
22.0 mm modeled sleeve ID − 21.34 mm reference OD = 0.66 mm nominal diametral clearance. Physical fit still requires verification.
01 / Illustrated concept
CAD Component Modeling & Interfaces
What the diagram means: Design hollow printed modules, physically removable connections, fin-locating slots and a separate grounded launcher reference in one Fusion assembly. The example values illustrate the principle and do not replace actual teacher-assigned dimensions.
02 / Watch and research
Instructional video and technical resources
Fusion components and joints
Use the relevant modeling or assembly technique; the demonstration project may differ from the rocket assignment.
Watch directly on YouTube ↗Expert references
Use these official Autodesk or NASA guides when the video alone does not explain the underlying workflow.
Primary technical reference ↗Additional learning resource ↗Self-study: identify a key technique, pause the tutorial, apply the operation and verify the result before continuing.
03 / Step-by-step guide
From theory to your own project
Guided task sequence
- Model lower launch/fin module, body and blunt nose separately
- keep basic walls approximately 1.2–2.0 mm
- create detachable couplers
- add 3 or 4 separate fin components.
Worked example and verification
22.0 mm modeled sleeve ID − 21.34 mm reference OD = 0.66 mm nominal diametral clearance. Physical fit still requires verification.
Important: Do not substitute illustrative numbers for actual CAD dimensions, real measurements or instructor approvals.
04 / Independent practice
Explore one key parameter
Interactive concept explorer
Illustrative values only; not a completed engineering inspection or teacher authorization.
Check your reasoning
Why does a section view matter?
It shows internal bores, wall thickness, coupler geometry and trapped features.
Is the grounded launcher reference manufactured as part of the rocket?
No. It models an external launcher interface.
Use the lesson's original assignment and “What to Submit” sections below for exact deliverable requirements.
Lesson Overview
What You Are Learning
Learning Targets
- Create each major rocket module as an identifiable Fusion component.
- Design removable printed-to-printed interfaces around intentional geometry.
- Model laser-cut fins at measured stock thickness.
- Use joints and controlled references to assemble the rocket.
Unit 3 Progression
The approved architecture from Lesson 3.6 becomes the working digital rocket.
ComponentsAssembleVerifyFabricateReviseFlight Test
Compressed-Air Rocket Challenge
Project Requirements
These requirements apply throughout Lessons 3.6–3.14.
1/2 in PVC Reference Tube
- The launcher tube outside diameter is 0.840 in (21.34 mm).
- Model the launch tube as a separate grounded Fusion reference component.
- You choose the rocket's internal launch clearance, but the finished rocket must slide freely over the actual PVC tube without binding.
- Before choosing the rocket's internal bore dimension, measure the actual unpressurized classroom launch tube. The 0.840 in (21.34 mm) diameter is the nominal outside-diameter reference, not the target bore size.
- The launcher itself is teacher equipment and is not modified as part of this project.
Modular 3D-Printed Rocket
- The structural rocket body is 3D printed in classroom-approved filament.
- Use at least 3 major printed modules: a lower launch/fin module, a main body module, and a nose/upper module.
- The rocket must have at least 2 removable printed-to-printed interfaces.
- Major printed modules must be disassembled without damaging the parts; permanent adhesive is not allowed between major modules.
Connection Method
- You choose how major modules connect.
- Examples include keyed/slip couplers with retention, twist-lock/bayonet features, screws/inserts, snap-fit features, or another approved method.
- The connection must keep the rocket aligned and secure during handling and flight-readiness checks.
- If a connection uses hardware or a tool, it must still be serviceable without damaging the printed parts.
Laser-Cut Fin Assembly
- Use 3 or 4 identical fins, equally spaced at 120° or 90°.
- Fins are laser-cut from 1/8 in acrylic or plywood.
- Use 3.175 mm as the nominal CAD thickness, then measure the actual stock and use that measurement for the final fin interface.
- Fins must use a repeatable locating feature such as slots, tabs, keyed pockets, or another approved feature. Surface gluing alone is not an acceptable locating method.
- Adhesive may be used to retain the fins after the fit/alignment check is approved.
Lightweight by Design
- Primary body walls should generally be 1.2–2.0 mm thick; 1.6 mm is the recommended target.
- Geometry thicker than 2.5 mm should be limited to local interfaces, couplers, fin mounts, fastener features, or other justified reinforcement.
- Total predicted 3D-printed material should be 100 g or less.
- The finished rocket should have a total mass of 125 g or less before the flight-readiness review.
Build for the Classroom Process
- Every printed component must fit the classroom printer build volume and be designed to print without support material.
- No support material may be required inside the launch bore or any mating interface.
- The nose must be rounded/blunt, and exposed fin corners/edges must be made safe before flight.
- Only the instructor operates, pressurizes, or changes settings on the compressed-air launcher.
Assignment
Build the Modular Rocket in Fusion
Create the complete rocket assembly while preserving the separation between manufactured components.
Step-by-Step Instructions
- Create the launcher reference: Model a simple 21.34 mm diameter cylinder as a separate component and ground it. Use the teacher-designated insertion length or reference geometry.
- Design the lower module: Create the launch bore/sleeve and the fin-locating geometry in the lower rocket component.
- Design the main body module: Use a hollow lightweight shell with primary walls generally between 1.2 and 2.0 mm.
- Design the nose/upper module: Use a rounded/blunt nose profile and include the selected removable connection to the body.
- Create the second removable interface: Design the connection between the main body and lower module.
- Model the fins: Create one fin component using the actual measured acrylic/plywood thickness, then place 3 or 4 identical fin components at equal spacing.
- Use joints: Apply appropriate rigid relationships or other required assembly constraints so the rocket components stay in their intended positions.
- Check serviceability: Confirm the major modules can conceptually separate without trapped geometry or impossible assembly order.
- Check material use: Remove unnecessary solid material and reserve thicker geometry for interfaces and local reinforcement.
- Save an assembled checkpoint: Finish with the rocket fully assembled around the grounded launch-tube reference.
Before You Submit
- The design is a true component assembly.
- At least three major printed modules are separate components.
- Two removable printed interfaces are modeled.
- The launcher reference is 21.34 mm OD and is a separate grounded component.
- Fins are separate components at the correct measured stock thickness.
- Body walls are lightweight and local reinforcement is intentional.
Submission
What to Submit
Submit only the following assignment-specific deliverables in Google Classroom:
Resources
Lesson Resources
IED Unit 3
Return to the Unit 3 lesson map and project sequence.
Introduction to Engineering Design
Return to the IED course hub.
Build your lesson report
Checkpoint: is your evidence ready?
- Check calculations, units, labels, and measurements against the activity requirements.
- Record what actually happened, including unexpected results.
- Explain what you changed and why; attach required drawings, photos, CAD, or code in your classroom assignment.
Submit only the following assignment-specific deliverables in Google Classroom: Fusion design (.f3d): LastName_FirstName_3_7_RocketAssembly.f3d with 3 or more individually named printed modules, two modeled removable connections, the fin components, rigid assembly relationships, and a separate grounded launcher reference. CAD evidence (one PDF): LastName_FirstName_3_7_CADViews.pdf with an isometric assembly screenshot including the Browser and two labeled section views—one for each removable interface. Label the fin count/material and launch-tu
A PDF download is not a submission. Review it, then upload it and any required attachments through your classroom assignment system.