Case study / Union College Rocket Team Deployable sensor payload

The event asks for a rocket that puts a custom built sensor payload into a five hundred foot window, drops it at apogee, sheds its nose cone partway down, and streams five channels of telemetry to a handheld ground station until it lands. We built CHARGER, and it won.

All work

There was no rocket team at Union College when I started. I founded it, ran it as captain and chief engineer, trained new members through build labs, owned NAR and Tripoli safety compliance for high power launches, and grew the budget by seven hundred percent by writing funding proposals. The team was chartered as an official section of the National Association of Rocketry.

Published by Union College and by the competition organizer.

1stDeployable Sensor Payload event
1.80 calStability margin, 37 inch airframe
13.8 ft/sDescent, against a 15 ft/s limit
$716Total hardware cost

The rocket flies a commercial G motor to between seven hundred and twelve hundred feet, drops the payload at apogee, and at seventy five percent of peak altitude the payload releases the nose cone, which has to reach the ground under fifteen feet per second on its own.

With the nose cone gone the payload exposes a camera and films the ground until it lands. Throughout, from the moment it goes on the pad, it transmits air pressure, altitude, acceleration, temperature and rotation rate to a ground station that has to plot all of it live and derive the descent rate as it happens.

01Commercial G motor. Apogee at least seven hundred feet and no more than twelve hundred
02Payload separates at apogee and descends at under fifteen feet per second
03Nose cone released at seventy five percent of peak, and it must land gently on its own
04Payload electronics must be custom designed. Commercial flight computers are not allowed
05Five sensor channels transmitted at two hertz or better, from the pad until landing
06Ground station portable, handheld antenna, two hours on battery, everything plotted live

The flight is worth two hundred and fifteen points, plus a tenth of a point per foot above seven hundred. Most of it sits on the data path rather than the rocket.

01Camera captures the ground from nose cone release until landing. 50 points
02Ground station receives and displays telemetry live, at least ten packets after liftoff. 30 points
03Altitude, acceleration, rotation rate and temperature each plotted in real time. 20 points each
04Descent rate calculated and displayed in real time. 20 points
05Nose cone released at seventy five percent of peak altitude. 20 points
06Apogee inside the window. 10 points, plus a tenth of a point per foot above seven hundred
07Payload deploys from the rocket at apogee. 5 points

Flight points are added to the design review scores rather than compared against them. A preliminary review is due in December and a critical review in March, both presented live to judges and both scored.

Radio and antenna trades, a power budget, a software state list, flight simulations, mass with the motor installed. The judges expect all of it written down months before anything flies, and they score it twice.

Thirty seven inches, single stage, 2.63 inches across, three trapezoidal balsa fins on a cardboard body tube. Centre of gravity at 22 inches, stability margin 1.80 calibres.

The body tube is cardboard because the payload transmits continuously from the pad to the ground. Carbon fibre would have put a conductive shell around a 2.4 GHz antenna. Cardboard is transparent at that frequency, so the radio set the airframe material.

An Aerotech G77R-7 at a thrust to weight ratio of 8.17, with a G79 held as backup at 7.40. Simulated apogee 1,033 feet, targeted mid window rather than near either limit. Descent 13.8 feet per second under a 48 inch ripstop nylon canopy, against a limit of 15.

01Length 37 in, maximum diameter 2.63 in, single stage
02Three trapezoidal fins, root chord 2.76 in, height 2.36 in, sweep 2.17 in
03Stability margin 1.80 cal, centre of gravity at 22 in
04Aerotech G77R-7, thrust to weight 8.17, burn 1.25 s
05Simulated apogee 1,033 ft, descent 13.8 ft/s on a 48 in parachute
06Rail buttons at 2 in from the aft end and 22 in from the nose, near the CG
07Rocket $465.42, payload $250.53, ground station $0.00 from existing kit

The rules do not accept a friction fit motor mount. There was no retention design at the preliminary review, so I drew a screw-on cap. The motor changed from a G80T to the G77R-7 in the same period, once the mass budget settled and the simulation had a real airframe rather than an estimate.

The rocket carries a commercial altimeter and does not use it for recovery. The event bans commercial flight computers in the payload, so every ejection charge fires off the team's own board reading its own barometric sensor. The commercial unit is there so a judge can read peak altitude off it after recovery, with the power still on.

The shock cord attachment carries the whole rocket at the instant the parachute opens. Peak simulated acceleration 24.4 feet per second squared on a 2.2 pound rocket is 19 pounds of force through an M3 screw with 0.11 square inches in shear. 1,641 psi against a 10,000 psi allowable, so six times margin.

CHARGER vertical on pad one at Battle of the Rockets, Culpeper, Virginia
Pad one, Culpeper, Virginia, April 2026

Three attempts per team, and the range closes at four in the afternoon. Weather can take the whole weekend, and if it does the awards are decided on the December and March review scores alone.

We got two clean flights away on the first day while the weather held, then put up the qualifying flight before noon on the second. One team member stands at the launch control officer's position as mission control and nothing leaves the pad until they say it does.

Final standings, published by Union College on 23 April 2026 and listed by the competition organizer.

01Union College Rocket Club
02Chantilly Aerospace Club Team 3
03Thomas Jefferson High School
04Spring Grove Area High School Team 2
05George Mason University

Competition rules allow only team members to work on any part of the entry: design, simulation, build, repairs, launch. Advisers guide and mentors review, but nobody outside the team touches the rocket.

That put the recruiting and the funding on the same critical path as the airframe. The proposals paid for the hardware, the build labs produced twelve people who could fly it, and the two design reviews forced the team to write down exactly how the rocket worked before it flew.

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