Mechanical Design & Prototyping

Mechanical Design & Prototyping

Stowage & Deployment Hat

Stowage & Deployment Hat

All images and work contained in this project are Intellectual Properties of Carnegie Mellon University. Unauthorized copy and distribution are strictly prohibited.

All images and work contained in this project are Intellectual Properties of Carnegie Mellon University. Unauthorized copy and distribution are strictly prohibited.

Moonranger is CMU's flagship autonomous lunar rover - designed to fly on Artemis manned missions with NASA and SPACEX.

Problem Statement

The rover lacked a stowage and deployment mechanism that enabled the astronauts to carry and deploy the rover on the lunar surface.

Challenges included the safety and efficiency of carry, the ergonomics of a pressurized space suit and launch load bearing capabilities.

My Contribution

  • User flow to understand critical pain-points

  • Co-designed a novel "hat" with unified lever mechanism to solve the problem of stowage and deployment.

  • Prototyped proof-of-concept using 3D Printing and Laser Cutting

  • Generated technical & design documentation

Impact

  • Demonstrated concept successfully with a working prototype

  • Enhanced astronaut ergonomics & safety

  • Concept was approved by NASA engineers for further R&D

The Process

A deeper dive into the broad steps that were taken to successfully develop the project

A deeper dive into the broad steps that were taken to successfully develop the project

UX Research

Conducted detailed user study - understanding behavior and SOPs of astronauts on a lunar mission and then designed a workflow with intermediate steps.

User Analysis | Storyboarding

Detailed CAD

Developed a CAD model with sub-assemblies and conducted 6 design reviews with iterative improvements.

Solidworks | Onshape | Renders

Fabrication

Fabricated the CAD design using rapid prototyping methods and validated functionality.

3D Printing | Laser Cutting | GD&T

Sub System Validation

Tested and validated all individual mechanisms and connections.

3D Printing | Laser Cutting | GD&T

Final
Proof of Concept

Final Proof of Concept

We developed a working proof of concept which was presented to senior leadership at NASA and was adopted further for R&D.

Technical Design Reviews | Technical Documentation

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