Breaking Barriers: Project Sunride Sets New Record

Congratulations to Project Sunride who successfully hot-fired their second regenerative-cooled liquid rocket engine at Airborne Engineering Ltd in Westcott, Buckinghamshire this month.

The student-built AlSi10Mg engine smashed its design target of 3.5kN (kilonewtons) to reach a record 4.4kN thrust, paving the way for the UK's first student launch of a liquid-fueled rocket this summer.

This achievement is a major leap in proving aluminium's viability for rockets despite its melting point challenges. Aluminium is lightweight and low cost, but prone to losing strength at high temperatures, but with the right cooling it works as the team has demonstrated.

In the context of rocket engines, "hot fired" refers to a test where the engine is ignited and run for a short duration under controlled conditions. This is done outside of an actual launch or flight to ensure all engine components are working properly as well as gathering performance data on thrust, temperature and other parameters to ensure the engine meets design specifications.

Hot firing is a crucial step in the development and testing process of rocket engines and allows engineers to identify and fix any problems before the engine is used in a critical situation.

Dominic Callister, Aerospace Engineering student and Sunfire Engine Team Lead, said: “Having developed and successfully tested this engine just eight months after the test of the previous engine is a huge achievement and a testament to the hard work of the team. Using the lessons learned from the previous hotfire, 'Sunfire III' managed to reach and exceed its design requirements, raising the bar of the highest thrust UK student engine to 4.4kN. We are very grateful for the invaluable advice provided from individuals in the space industry and amateur rocketeers alike that allowed us to develop this engine. I'm looking forward to testing this same engine again in the future!”

Oliver Dew, General Engineering student and Chief Propulsion Engineer for Sunride, said: “After three years of developing a reusable liquid rocket engine, we are incredibly proud to have completed three successful tests of our 'Sunfire III' engine! Our engine’s success has been a culmination of all the lessons learned and experience from past years and the support and opportunities provided by the university and industry. As well as demonstrating the capability of an alternative material for high temperature applications, our students have also gained skills needed for the rapidly growing UK space sector.”

Dr Alistair John, Deputy Director of Aerospace Engineering, said: “Not only did the engine achieve far higher than its rated thrust, it also survived three hot firings with combustion temperatures exceeding 2750K. It is completely unscathed, demonstrating its reliability and readiness for reuse. Congratulations to the Sunride team! It's amazing how far we have come in the last few years.”

Formed in 2017, Project Sunride is a student-led rocketry team at the University of Sheffield and they currently hold the UK Open Altitude record at 36,274ft, which the team achieved in 2019 with their rocket "Helen".

Find out more about the team on their website.