Prometheus Rocket Structures FEA And Composite Airframe Design
Jeremy Sabot
Project Timeline
Sep 2025 - Current
OVERVIEW
I led the airframe and Stage 1 booster structural design for PROMETHEUS, a two stage Level 2 high power rocket targeting 20000 ft. My responsibilities included load path design for thrust transfer, composite fuselage sizing, structural analysis in ANSYS Workbench, aerodynamic stability support, and design iteration through engineering reviews. The goal was to produce a flight ready structure with defensible margins for launch loads and aerodynamic loading, with a clear path for validation testing.
HighlightS
- Led Stage 1 booster and airframe structural design for a two stage Level 2 rocket targeting 20000 ft and integrated interfaces for Stage 2 active guidance canards
- Designed the thrust load transfer architecture including motor mount and centering ring structure for a 54 mm L class booster motor with max thrust about 1355 N
- Performed structural FEA in ANSYS Workbench 2025 R2 to identify stress concentrations and reinforce critical joints and load paths
- Supported aerodynamic stability sizing including fin sizing and static stability margin target around 1.5 calibers and performed flutter screening checks
- Created design review documentation of assumptions, load cases, results, and design changes to guide build and validation testing
SKILLS
ANSYS WorkbenchFEAComposite StructuresStructural AnalysisLoad Path DesignSolidWorksAerodynamic StabilityFlutter AnalysisDesign ReviewsSystems IntegrationTest PlanningManufacturing For Assembly
ADDITIONAL CONTENTS
Jeremy Sabot
Mechanical Engineer | Aerospace Propulsion
I'm a mechanical engineer with strong expertise in CAD, FEA, and CFD analysis, currently pursuing advanced studies in aerospace engineering. I have hands-on experience designing and validating complex systems, from water distribution test sites to high-power rockets. My background spans product design, manufacturing processes, and structural analysis, with proven ability to lead technical projects and collaborate with senior engineers.
I'm a mechanical engineer with strong expertise in CAD, FEA, and CFD analysis, currently pursuing advanced studies in aerospace engineering. I have hands-on experience designing and validating complex systems, from water distribution test sites to high-power rockets. My background spans product design, manufacturing processes, and structural analysis, with proven ability to lead technical projects and collaborate with senior engineers.