Project Thorondor

Thorondor Logo

4^th Generation SRAD
Hybrid Rocket

EJECTION INSTRUMENTS ARMED

DO NOT PASS IN FRONT OF NOSE CONE

Introducing Thorondor MARK II

Project Thorondor Mk.II represents the culmination of our first hybrid rocket development campaign, building on the legacy of past successful projects like Athos, and Porthos. This iteration features a robust design with carbon fiber and glass fiber aerostructures, custom-designed flight computers for precision control, and a sophisticated ground support system. Our hybrid engine utilizes nitrous oxide and paraffin wax, providing reliable propulsion, while a multi-stage recovery system ensures safe return with both custom and commercial parachutes.

Thorondor Mk.II incorporates significant advancements, including pre-impregnated body tubes for enhanced strength, a refined flight computer architecture with a Real-Time Operating System, and optimized fluidic and intertank layouts. Despite a tight development schedule, we've proactively mitigated risks by extensively flight-testing critical components like the main oxidizer valve and radio modules. Lessons learned from previous missions have been directly applied, ensuring improvements in areas such as parachute deployment and igniter safety, positioning Thorondor Mk.II for a successful flight at Launch Canada 2025.

MISSION PATCH

SYSTEMS OVERVIEW

AE Aerostructures AV Avionics PL Payload PR Propulsion LS Launch Systems RC Recovery

Aerostructures Subsystem

Thorondor Mk.II incorporates a meticulously engineered aerostructure, integrating advanced materials and validated design methodologies to meet stringent performance and safety requirements.

External Airframe Composition

The primary airframe consists of a Glass Fiber Reinforced Polymer (CFRP) tube, selected for its radio-transparent properties to optimize communication with internal avionics. The propulsion combustion chamber is encased within a Carbon Fiber Reinforced Polymer (CFRP) tube, chosen for its superior strength-to-weight ratio under high-temperature and pressure environments.

Internal Structural Integrity

All internal load-bearing components, including fasteners, attachment points, and bulkheads, are custom-designed by the MRT team. Each element undergoes rigorous validation through empirical testing or finite element analysis (FEA) to confirm a minimum safety factor, particularly under off-nominal load conditions such as recovery system deployment shocks.

Avionics Subsystem

The Avionics & Telemetry system manages onboard control and monitoring functions of project Thorondor Mk.II, and communicates system and mission data to the ground station for real-time monitoring and post-flight analysis.

Electromagnet Remote Arming

For safety reasons, the rocket cannot be armed by hand once it's placed on the launch pad. Instead, the team uses a remote-arming system. Electromagnets are attached to the launch tower and controlled from a safe distance. When the operators flip a switch, these magnets activate corresponding magnetic switches inside the rocket, arming all systems for flight.

Triple Redundant Recovery System

The rocket uses a Missile Works RRC3 Sport altimeter as a commercial-off-the-shelf flight computer to satisfy competition requirements. There are also two two separate student researched and designed flight computers running separate software. Any of the three flight computers are able to independently fire energetics to deploy both the drogue and main parachutes. Both FC’s are tested using a Hardware In Loop (HIL) tester, which feeds the flight computer telemetry data and tests to ensure nominal recovery deployment.

Enhanced Power & Tracking

To save its onboard batteries for the flight, an external power cord (an umbilical) is used while sitting on the launch pad. A power-switching circuit automatically disconnects from the umbilical at liftoff and seamlessly switches to its two onboard batteries as needed. For tracking, a high-sensitivity GPS module sends the rocket's location to the ground station.

Ground Station & Communications

Live telemetry from the rocket’s flight computer is transmitted to the ground station via LoRa radio. The ground station GUI parses, displays, and records this data in real time, giving operators full visibility of the rocket’s status. Commands can also be issued through the GUI, sent via the ground station radio, and received by the rocket. A two-way handshake with acknowledgments confirms reception of each command, allowing operators to retransmit if failed.

Two team members tabling at an event with a used rocket.

Payload Subsystem

Advancing Orthopedic Science Rocketry

Our payload is an advanced biomechanics experiment exploring how the forces of launch—acceleration and vibration—impact the fixation strength of orthopedic screws, comparing the surgical standard adhesive PMMA with a novel, non-toxic alternative called Tetranite. Positioned securely between the vent and avionics sections, it houses carefully prepared canine vertebrae under the guidance of a spinal surgeon, fully isolated from electronics and hazardous systems for the entire flight.

Safety First

A precision thermoelectric cooling system preserves the samples, while electronics mounted above manage data storage and real-time transmission via CANbus, along with power switching between onboard battery and pre-launch umbilical. By using medically inert materials, fully containing all fluids, and conducting rigorous pre-flight checks, the design ensures maximum safety for both the vehicle and personnel while delivering valuable scientific insights.

Propulsion Subsystem

The propulsion system creates the thrust that launches the rocket and propels it to its apogee. As with previous MRT hybrid engine rockets, the propulsion section has four main parts:

1. Vent Section

This section contains the tank's vent line and a pressure relief valve, which opens if the pressure gets too high (820 psi), just below the maximum operating pressure of 850 psi. This ensures that if the pressure reaches the maximum, enough gas can flow out. This section also includes a sensor for the oxidizer tank pressure and a temperature sensor on the vent valve exhaust.

2. The oxidizer tank

This tank holds the oxidizer (N₂O) and connects to the vent and intertank sections. The oxidizer is crucial for combustion, providing the necessary oxygen for the fuel to burn efficiently. Its proper containment and delivery are vital for rocket performance.

3. The intertank

This section houses the system that controls the flow of oxidizer. This includes the Main Oxidizer Valve (MOV), which allows oxidizer to flow from the tank to the engine, and the Fill/Dump Oxidizer Valve (F/DOV), which controls oxidizer going into and out of the rocket. It also contains the piloting valves that operate the MOV and F/DOV's pneumatic actuation.

4. The thrust chamber assembly

Called Maelström Mk.III, this section includes the front interface (with the injector), a middle section containing the fuel, and the rear interface (with the nozzle). It is protected by a heat-resistant liner inside a commercial off-the-shelf rocket casing.

Launch Systems

Launch Systems is the team that makes sure everything on the ground is ready for a smooth and safe rocket launch.

Launch Tower

The main function of the launch tower is to allow a launch angle of 84° with respect to the horizontal during liftoff, while supporting the rocket’s full mass. This system was designed to be assembled and disassembled by 5-6 operators in 4-5 hours on the launch pad.

Fill System

The fill system is used to load the rocket’s tank with oxidizer and safely disconnect it before launch. It is made up of support equipment, plumbing for transferring the oxidizer, and a mechanism that detaches the system when needed. Special stands and jigs are used to hold and flip the oxidizer bottles into position, with locks and straps to keep them secure. The plumbing includes valves, sensors, and safety features that control the flow, monitor conditions, and provide backup options in case of issues.

Disconnect Mechanism

The fill disconnect is the system that detaches the oxidizer line from the rocket before launch. It uses a linear actuator to release the connection and pull the line away, making room for the rocket’s fins. The setup ensures the line separates cleanly and safely without manual intervention. Adjustable components help keep the system aligned so the release works reliably every time.

Recovery Subsystem

The recovery subsystem is responsible for safely landing and retrieving the rocket.

Ejection

When the rocket reaches its apogee, the recovery system uses black powder to trigger an ejection of the system. This reaction takes place in the ejection chamber, which acts as the site of separation between the nose cone and lower body of the rocket. For redundancy, the two black powder charges are wired in parallel.

Drouge Parachute

The drogue parachute deploys at the target apogee via black powder ejection, whereas the main parachute is designed to deploy at 1500 ft (457 m) via a 3-ring release mechanism. It is designed in-house by the team, and was manufactured during the 2023/2024 year for Project Thorondor. It was originally created as part of the subteam’s effort to transition away from commercial parachutes, with the goal of building flight-ready, student-fabricated recovery subsystems.

Main Parachute

The main parachute selected for Thorondor Mk. II is a commercial off-the-shelf (COTS) parachute purchased from Fruity Chutes. This parachute was chosen for its reliability, compact packing volume, and high drag coefficient. It is a 12-gore annular toroidal parachute made of high-performance ripstop nylon, equipped with 400 lb Spectra shroud lines and a 1/4 in Kevlar bridle. The system comes pre-assembled and integrates a top loop for use with deployment bags.