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Role: Mentor, Scope Owner
Duration: September 2024 – May 2025
Requirements: Develop a quick disconnect that allows for bidirectional flow at every moment up until launch, but disconnects passively once the engine is lit.
Summary: Mentored a new member of the team in the development of a high pressure gaseous nitrogen quick disconnect. As subteam lead, I owned the scope of this project and was ultimately responsible for integration and successful operation during launch. The QD was operated successfully in a June 2025 launch with no damage.
Article: Several designs were explored in the trade space, including complex mechanisms, valves, and pyrotechnics. FAR-OUT rules required that we maintain manual abort capability until the rocket is under thrust, which means ground drain capability. A pneumatic, electromechanical, or pyrotechnic mechanism was not preferred due to the extensive testing required to de-risk operation during launch. If the QD failed, the rocket was already under thrust and it would take our GSE with it.
The final design was simple and robust. It utilized a 3/8″ Swagelok check valve rated for 6000 psi, and a machined inhibitor held the check valve open throughout pressurization (allowing for ground drain capability). Swagelok did not model the check valve internals in their CAD, so we made manual measurements. At launch, the clip retaining the inhibitor to the check valve would be removed as the vehicle ascends under thrust. Pressure would then force the mechanism apart, the check valve would seal, and the vehicle would ascend.
I mentored the Responsible Engineer in developing all analysis for o-ring friction, stress in the QD components, clip friction, tolerancing, and manufacturability.
We hydrostatically testing the assembled mechanism to 6000 psi, verifying it is structurally sound and the backup rings prevented o-ring extrusion.
