Estes Style Rocket | Working, Fully 3D Printed & No Supports Needed

I was tasked with making a fully 3D printed model rocket for a class. It’s designed to work with Estes B6-4 or A8-3 model rocket motors, as well as any others that fit the standard 18mm x 70mm size. I spent about a week modeling and making test prints to get parts that fit together well, looked good, and could be printed without any supports. I'm proud to say that the project was a huge success! My rocket flew highest out of all of the people competing and even came back so we could launch it again.

This project was an absolute blast, and I wanted to share it with others who love rocketry as much as I do. If you decide to print and launch this design, please post a make. I’d love to see your results!

Print Settings (0.4mm nozzle):

Nose Cone: 2 Walls, 0% infill

Fuselage: 2 Walls, 10% infill

Motor cap: .1mm Layer height, 2 Walls, 15% infill

Fins: 3 Walls

Assembly:

• Attaching the fins: The fins are designed to press-fit into the fuselage. While they should stay in place during normal handling, applying adhesive can help secure them more firmly, preventing them from dislodging upon impact when the rocket lands.
• Securing the motor cap: The motor cap simply screws onto the designated mounting point. Ensure it is tightened properly to keep the motor in place during launch and flight.
• Installing the nose cone: The nose cone fits snugly into the fuselage via a press-fit connection. Make sure it is seated firmly to maintain aerodynamic stability.
• Parachute: The nose cone features a hook designed for attaching a parachute. Secure the parachute either by tying it directly to the hook or using the recommended attachment method specific to your parachute model.
• Shock Cord: To ensure the parachute remains connected to the rocket, attach a shock cord to the same hook as the parachute. Follow the provided image or instructions to properly glue the cord to the interior of the fuselage for stability.

Launching the Rocket:

⚠ Before launching your model rocket, always check the weather conditions. Avoid launching in strong winds, rain, or storms, as unpredictable weather can affect flight stability. Make sure your launch site is clear of obstacles like trees, power lines, and buildings, and ensure there are no people or animals nearby. A safe, open area is essential for a successful and controlled flight. ⚠

• Motor Installation: Unscrew the motor cap from the fuselage and carefully insert the rocket motor, ensuring it is oriented correctly. Once positioned, securely screw the cap back on.
• Starter & Plug: Insert the starter and plug into the rocket motor.
• Launch Controller Connection: When connecting the two wires to the launch controller, ensure they are not touching to prevent a short circuit.

This model rocket was designed with care, but by launching it, you acknowledge the inherent risks involved. I am not responsible for any accidents, malfunctions, or unexpected outcomes that may occur. Always follow safety guidelines, check your surroundings, and ensure proper launch conditions. Additionally, the instructional images included were sourced online and are the property of Estes Rockets. Please fly responsibly!