Aerospace Designs

GPS Antenna Test Hat

Created the structure of this design using PA 4035 CF 3D Printed polymer by Jabil industries, selected for it’s Electrostatic Discharge (ESD), strength, and thermal, properties. This design is suitable for interfacing with highly sensitive electrical components on space rated flight hardware components intended for Low Earth Orbit.

The inside of the chassis houses a commercial off the shelf antenna probe capable of relaying GPS signals via simulation to aid in aliveness testing frequencies for hardware testing events.

This design offered a bespoke solution for a very intricate mounting point on the space vehicle and saved the program over $20k in cost by implementing this solution across the test fleet.

GPS Test Hat Bill of Materials (Click Me!)
  • Qty. 1 – 100 g of Jabil PA 4035 CF 3D print polymer chassis
  • Qty. 2 – #8-32 x 0.375 SHCS fasteners
  • Qty. 1 – GPS (L1/L2) Antenna probe (COTS)
  • Qty. 1 – 8″ strip of flight rated aluminum tape
  • Qty. 1 – Male-to-Male coax RF adapter
Mechanism Torque Jig Bill of Materials (Click Me!)
  • Qty. 2 – toggle clamps
  • Qty. 8 – M4 x 12 mm SHCS fasteners
  • Qty. 8 – M4 nuts
  • Qty. 4 – M2 x 8 mm SHCS fasteners
  • Qty. 4 – M2 brass heated inserts
  • Qty. 1 – mounting base (PLA polymer)

Mechanism Torque Jig

Clamping tool to aid in applying high torque to aerospace component prior to installing on to flight vehicle.

Utilized commercial off-the-shelf (COTS) toggle clamps and 3D printed base that can attach to any workstation and allow the technician to align the component in the fixture and alleviate any rotation of the component to achieve torque value.

Not only was this solution effective, it saved the program scope and cost to get the parts ordered rapidly and fit checked in time to prep a vehicle for launch call-up.

Further Aerospace Work?

Because of the sensitive nature of my work on classified programs, I’m unable to share more details about the design projects I’ve been fortunate to contribute to. However, I’d be happy to discuss my technical skills and experiences at a high level while maintaining the confidentiality of these critical applications. For any questions about my background, please don’t hesitate to reach out through my contact page!