Project Overview
Designed and manufactured precision clamping solutions for the rocket avionics bay enclosure. Working with a team, we created a multi-part clamping system to securely hold shells, plates, and internal components together while maintaining a watertight seal for flight operations.
The Challenge
The avionics bay required:
- Precision clamps to hold enclosure components under pressure
- Watertight seal integrity during flight
- Reliable fastening that could withstand vibration and thermal stress
- Efficient manufacturing of multiple similar components
Clamping System Design & Manufacturing
Fusion 360 CAM & CNC Milling
Designed clamps in Fusion 360 and programmed CNC mill operations:
- Optimized clamp geometry for load distribution
- Generated efficient tool paths for CNC production
- Programmed multiple operations from single stock
- Achieved tight tolerances on critical surfaces
Packing Factor Optimization
A key achievement was condensing multiple clamp parts into a single CNC operation from one piece of stock. This packing factor approach:
- Reduced material waste and production cost
- Minimized setup time with single clamping
- Ensured consistent geometry across all parts
- Decreased production time by optimizing tool paths
Radial Hole Fixture & Secondary Operations
Laser-Cut Fixture Design
Created a custom fixture for radial hole drilling:
- Designed fixture geometry for precise hole positioning
- Optimized for laser cutting from acrylic or aluminum sheet
- Enables repeatable drilling and tapping on manual mill
- Quick-change design for efficient workflow
Radial Drilling & Tapping Operation
Using the custom fixture on the manual mill:
- Drilled radial holes at precise angles and depths
- Tapped threads for fastener installation
- Maintained tight tolerances across all radial features
- Repeatable process for consistent quality
Assembly & Integration
Collaborated with the team to assemble the complete avionics bay:
- Coordinated clamp installation with enclosure shells
- Integrated internal plates and mounting hardware
- Verified watertight seal integrity
- Tested assembly under simulated flight conditions
Results & Achievements
Project Outcomes
- Successfully manufactured precision clamps meeting all specifications
- Completed assembly across multiple components made from different materials
- Delivered ready-to-fly avionics enclosure
Key Skills Demonstrated
CAM Programming
Fusion 360 CAM optimization, multi-part programming, tool path efficiency
CNC Milling
Precision operations, material optimization, tight tolerance work
Fixture Design
Custom jig design for laser cutting, repeatable processes, quick-change systems
Team Collaboration
Cross-functional assembly, integration coordination, quality verification