ULA Bracket - Space Racer

grabcad

The Space Racer bracket weighs only 0.090lb and successfully passes the load condition based on my specified configuration. I conducted a simulation utilizing a 'Titanium' jig and load applicator, ensuring that all contacts remained unbonded. Initially, I employed a plate to apply force; however, I discovered that both the plate and applied force would rotate under flexure. Consequently, I opted for a pressure plate restricted to vertical movement, simulating actual load testing conditions. Several animations within the files demonstrate stress propagation within the part. Although lacking specific information from ULA, my design constitutes a well-informed assumption. Regarding 3D printing, I would prioritize maximum strength by tailoring print direction accordingly, despite potential inefficiencies in material and time usage. This is justified due to the small size of the part, rendering wasted support material negligible. Moreover, this print orientation allows for increased part nesting per build. All design and validation processes were executed using Autodesk Fusion 360, resulting in approximately 50 hours of work across 56 iterations, with meticulous manual manipulation of the mesh. I thoroughly enjoyed this experience, and extend my gratitude to the sponsors for facilitating our contribution to a commendable cause.