Use Case: WARR Launches Rocket with Machined Parts

Pushing the boundaries of space technology requires innovative thinking and the right tools for the job.

The Scientific Workgroup for Rocketry and Spaceflight (WARR) at the Technical University of Munich launched their cryogenic rocket 12.7 kilometers above the earth. See how the group transformed “Project Cryosphere” from an idea to a reality with critical parts made by MakerVerse.

Industry

Aerospace

Location

Munich, Germany

Organization size

250 people

Use case

End-use parts

Technology used

CNC machining

Material used

3.4365 Aluminium zinc alloy

Parts produced

Connectors for a cyrogenic rocket that withstand high supersonic flight

Results

With short lead times and expert guidance, WARR gained precisely-manufactured parts

Working closely with MakerVerse on this project was so helpful. The personal touch and technical expertise made all the difference, and I look forward to working together again.

Francesco Longhetti

Head of WARR Rocketry

The Challenges: Blasting Beyond 12 KM

Since its foundation in 1962, WARR has been no stranger to ambitious space-related projects. Within that group is WARR Rocketry, whose student members come from all backgrounds ranging from mechanical engineering to business.

The team’s previous altitude record was 4 kilometers. With Project Cyrosphere, they wanted to go far beyond. WARR knew they needed an impeccable design and perfect parts to achieve that goal.

One of the significant challenges is the extreme conditions that the rocket would undertake. The 135-kilogram rocket would travel 3.5 times the speed of sound, undergoing intense strain until reaching the apogee. Every part must be precisely manufactured to handle severe heat and cold.

Furthermore, the student group faced tight deadlines to complete the rocket in time for the scheduled launch in California (US).

Project Cyrosphere successfully takes off. Photo credit: Matthew Swenson.

The Solutions

WARR’s rocket is made largely of carbon fiber, as this material combines strength with reduced weight. For the crucial connector interfaces, which connect the carbon fiber with the cryogenic tank and the upper segments of the rocket, WARR turned to MakerVerse.

With MakerVerse’s on-demand manufacturing platform, WARR gained access to the full range of manufacturing technologies and materials. In this case, CNC machining created these aluminum connectors to exact specifications. Considering the delicacy and difficult conditions, MakerVerse’s attention to detail was critical.

Throughout the process, MakerVerse provided very clear pricing and communications, which helped ensure all lead time expectations were met.

WARR prepares for the launch at the Mojave Desert launch site in the US.

The Results: Reaching for the Stars

With the successful launch of its cryogenic rocket WARR, gained invaluable date on supersonic flight and the performance of the hardware. This data will be put to use for other projects.

The team already has other ambitious projects planned for the near future, including innovative new rocket designs. For these projects, WARR plans to work with MakerVerse again using a combination of additive manufacturing, CNC machining, and other technologies as needed.

“MakerVerse was a great partner for our manufacturing projects,” said Francesco Longhetti, Head of WARR Rocketry. “They helped save us a lot of time.”