ULA Bracket Redesign

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The redesigned boattail support bracket for ULA Rocket Hardware Challenge features a mass-minimized, two-piece structure with bolt holes surrounded by material cylinders. An internal pocket of material has been removed to reduce weight further, a feature only achievable through additive manufacturing. No support material is needed within the pocket when oriented correctly. A small display stand for mounting the bracket can be 3D printed and modified as desired. A prototype was successfully 3D-printed using an ABS plastic with breakaway support material, confirming its buildability and removability of support material without damage. The part's mass is 0.099 pounds, volume is 2.042 cubic inches, and maximum stress at a 600 lbf load is 3838 psi. 3D printing calculations indicate total support material as 0.62 cubic inches and print time of 4 hours using Ultem 9085 material. Given information states material strength allowable as 4500 psi, specific gravity as 1.34, Poisson's ratio as 0.41, and Young's modulus as 325 ksi.