Archives

Project Details

Fabric 1

Silicone
Producer:

Fabric 2

Strands of silicone
Producer:

Subcontractor Company
AR Tech

Project Manager Name
Jessica Foley

Project Manager Company
AR Tech

Please describe the project specifications

The valve system for Payload Fairings (PLF) on space launch vehicles protects the rocket from debris, while allowing the pressure build up inside the fairing to be released.
During a launch, a large amount of debris rises from the ground and pressure builds up in the PLF (aka “nose cone”). The intelligent operation of this valve system assembly allows the valve not only to open to let the pressure inside the payload fairing escape, but also closes to prevent debris from coming in.
If debris where to enter the PLF, the launch would be disrupted and destroyed because the debris would contaminate the satellites being launched, at a cost potentially reaching $800 million.

What is unique or complex about the project?

These valve systems play a crucial role in space launch vehicles. The valve systems are a result of a collaborative development by our company and our customer, and stand out because of how essential it is for a rocket launch to be successful.
It’s a small component that plays a huge role.

Manufacturing this valve system requires considerable capability and a combination of meticulous hand sewing and taping.
Assembling each valve piece is very laborious. From cutting, to taping, to stretching the silicone bands 30 times each, to hand sewing & threading, creating knots and finally assembling everything together to create a valve system. Every step must be thoroughly completed as described in the manufacturing control plan to ensure the project meets supplier requirements. For example, one of these steps is stretching each silicone band exactly 30 times at a specific length before being used on the valve system. Any deviation from this can cause it to fail.
This is a very tedious project that was completed by our aerospace staff. Aerospace staff’s capability and knowledge is essential to crafting these valve systems.

Content is submitted by the participant. IFAI is not responsible for the content descriptions of the IAA award winners.