Subsystem integration and reliability in a high-power rocket payload

Abstract

This thesis investigates subsystem integration and its impact on reliability in a high-power rocket payload developed for NASA's Undergraduate Student Launch Initiative (USLI). High-power student rockets operate under severe mechanical, thermal, and electrical constraints, where failures frequently emerge at subsystem interfaces rather than with individual components. As part of a multidisciplinary USLI team, an electrical payload subsystem was designed, integrated, and tested within a full-scale competition rocket. The work focuses on the interaction between electrical, mechanical, and software subsystems, with particular attention to power distribution, sensing, communication, and structural interfaces. A system-level integration and verification methodology was applied, including iterative design, environmental testing, and failure analysis. Observed failure modes were documented and traced to interface-level design decisions, motivating targeted redesigns and integration improvements. Results demonstrate that subsystem integration quality is the dominant factor governing payload reliability in USLI-class rockets. The findings highlight the importance of interface definition, verification-driven design, and cross-disciplinary coordination in small-scale aerospace systems. In addition to technical outcomes, this project contributed to the development of professional engineering competencies in systems thinking, documentation, and reliability-focused design practices.