SpaceX Internship Projects
Engine Acoustic Analysis
​Raptor Propulsion - Spring 2018, Summer 2018, Summer 2019
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Acoustic modal analysis using ANSYS Acoustics package for the following Raptor flight engine components:
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Oxygen preburner​
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Oxygen preburner fuel manifold
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Oxygen turbine housing
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Main thrust chamber
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Complete oxygen system model below pumps and above thrust chamber throat
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Assisted in identifying modes contributing to damage during engine tests
Tank-Press Heat Exchanger
​Raptor Propulsion - Summer 2019
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Complete design, analysis, and build of oxygen system tank press heat exchanger used on the Raptor engine
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Took design from concept to fabrication in 12 weeks
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HEX model required estimated flow rates, pressure drops, and temperature gains using cross-flow heat exchanger theory
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ANSYS thermal and structural analysis for verification​
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DMLM printing for oxygen-resistant parts
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Brazing required for guaranteed rigidity (ignition hazard in high pressure & temperature oxygen)
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Heavy usage of 3-axis mill & lathe using carbide-tipped cutting tools
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Learned process of braze preparation, braze alloy application, and furnace heating procedure
Vacuum Nozzle Manufacturing
Raptor Propulsion - Summer 2019​
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Part of a small, agile team exploring early manufacturing methods for Raptor Vacuum engine nozzle extension
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Required cheaper and more effective option from traditional C103 Niobium
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Developed cheap, efficient, and effective method of manufacturing extension nozzles
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Reduced cost and technician time from C103 nozzle manufacturing by an order of magnitude
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Learned orbital tube welding process and practiced on many miles of joined SS 316 tube
Water-Flow Ox and Fuel Pump
Raptor Propulsion - Summer 2018​
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Responsible for complete design and manufacturing of sub-scale oxygen and fuel water-flow pumps for off-engine pump performance testing
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Required tight tolerancing using GD&T for shaft parts, seals, etc.
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Required pump scaling equations and flow path sizing using incompressible flow theory and pump performance theory
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Used 5-axis EDM and 5-axis mill to create and replicate complex on-engine fluid geometries
Engine Bolted Joint Analysis
​Raptor Propulsion - Spring 2018, Summer 2018, Summer 2019
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Responsible for tracking and structural analysis of all bolted joints on the Raptor flight engine
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Built tool tracking and feeding inputs of structural analysis for each bolted joint intoanalysis program and recorded outputs for real-time analysis results based on input variation
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Allowed for Responsible Analysts to easily look up joint confidence given proposed operating conditions
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Maintained this tool over multiple engine configurations
Oxygen Preburner Testing
​Raptor Propulsion - Spring 2018
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Junior Responsible Engineer for test stand
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Designed, analyzed, and tested preburner thrust takeout structure
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Designed and fabricated igniter tube assembly, purge tube assembly, and other ancillary systems for testing
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Provided on-console, real-time structural analysis in ANSYS for stand modified parts in high stakes situations in order to meet testing window
Purge Check Valve Design
​Raptor Propulsion - Spring 2018
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Worked with Marotta to up-rate check valves for 75% higher pressure and much higher temperature operation from Raptor development engine to flight engine
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Updated valve bolted joint
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Changed valve seat angle and modified cracking pressure
Test Stand Water Safing
Raptor Test Equipment - Fall 2017​
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Designed and built the then-in-development Raptor test stand water flow/fire suppression system for engine testing and component bay testing
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Provided analysis for "lights out" complete valve authority loss cases
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Sized system for all required surface area coverage and water flow in event of pressure-only tank control
Liquid Oxygen Service Lines
Raptor Test Equipment - Fall 2017​
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Provided analysis for critical insulation level based on denser liquid oxygen and required test stand service temperatures
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Designed and built 300 ft long service piping to various component level test articles
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Designed and safed LOx dump lines for these test articles as well
Test Stand Work Deck
​Raptor Test Equipment - Fall 2017
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Built a large, multi-person work deck as my first project at SpaceX
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Designed to factors of safety of 3 on yield and 5 on ultimate
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Accommodated for very large flow pipes and already in place flow service
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Performed structural analysis on entire structure including non-linear buckling analysis on support beams