This week the FLARE team focused on final data analysis and project closeout. We completed analysis of our experimental results and used the data to refine both our sub-scale and full-scale models. Key performance metrics, including power-to-weight ratio, power density,… Read More

This week the FLARE team conducted final testing while addressing key technical challenges. During initial high-temperature testing, an issue with RTV sealant required adjustments to our thermocouple setup to ensure safe and reliable operation. Following this, we achieved stable temperatures… Read More

This week the FLARE team focused on integrating the testing setup into the wind tunnel and preparing for final data collection. We completed installation of the system and conducted initial heating tests to verify operation in the tunnel environment. During… Read More

The team successfully assembled the primary hardware prototype, including the base plate, CNC-machined top plate, and custom copper heat sinks. During Tuesday’s inspection, a live thermal demo confirmed the PID controller could maintain target temperatures. Bench testing showed the electrical… Read More

This week the FLARE team made significant progress toward final system integration and testing readiness. The electrical box wiring was completed, enabling power regulation through the Raspberry Pi, with the system operating on a 20-amp circuit and 12-gauge wiring for… Read More

This week the FLARE team completed several key steps toward final system assembly and testing readiness. The junction box was fully assembled, integrating the electrical components needed to control and power the heating cartridges. The heating cartridges were also tested… Read More

This week the FLARE team encountered manufacturing delays due to equipment issues in the campus machine shop. The VF-3 CNC mill required for machining the top plate is currently out of service because of a broken spindle, temporarily halting final… Read More

  This week marked major progress in manufacturing and system integration. The bottom plate of the testing apparatus was fully machined and completed, and CNC tooling was developed for the top plate, which is scheduled to be machined shortly. We… Read More

This week centered on final assembly planning, electrical integration, and manufacturing coordination. CAD updates incorporated standoffs, fasteners, copper heat sinks, and finalized cable gland placement to manage approximately 25 system wires. The electrical configuration was refined, wiring four heaters in… Read More

This week focused on finalizing the heating solution and advancing the mechanical design toward manufacturing. The team refined the aluminum top plate design into a longer single-row configuration and completed the CAD model in preparation for CNC machining. Updates included… Read More

This week, the FLARE team tested the hot plate heating capabilities and identified major limitations in the current design. The hot plate was unable to reach the required testing temperature and posed a safety concern, as it could potentially damage… Read More

This week, the FLARE team presented our first Quarterly Review Board (QRB 1), where we outlined our testing plan, current design direction, and overall project outlook. The presentation allowed us to clearly communicate our progress and receive targeted feedback on… Read More

This week, the FLARE team met to develop and finalize our Bill of Materials (BOM), resulting in the ordering of most major components needed for our prototype. We met with our GE Aerospace liaisons to walk through the progress we… Read More

On Monday, 1/20/2026, the FLARE team met up to kickstart our preparations for the second semester of IPPD, outlining our plans and scheduling our meetings for the rest of the semester. The mechanical engineers of the team later met again to discuss… Read More

This week, we reviewed feedback from both our Peer Review SLDR and our coach. We were commended for implementing PID revisions effectively and delivering a more polished presentation. Our coach recommended adding an airflow-direction arrow to our model and expanding… Read More

On Tuesday, 11/18/2025, the FLARE team met to finish preparing for our Peer Review SLDR presentation. We worked on finishing both our SLDR report draft and the presentation to clearly communicate our current design and testing plan. Moving forward, we… Read More

On Monday, 11/10/2025, the FLARE team met to continue preparing for our Peer Review SLDR presentation. We worked on drafting our SLDR report and refining the presentation to clearly communicate our current design and testing plan. We also met with… Read More

This week, we presented our current design iteration for Prototype Inspection Day. We received a lot of beneficial feedback from subject matter experts. We’d like to thank all who attended. Moving forward, we plan on developing a CAD model for… Read More

On Tuesday, 10/28/25, we met as a group to discuss updating our plan for protype inspection day (PID). We used our coach meeting to discuss preliminary testing schematics we created and got beneficial feedback. A large part of this discussion… Read More

On Tuesday, 10/21/25, we met as a group to discuss updating our PDR, create a testing plan, and outline our required materials for prototype inspection day. We ordered a TEG demonstrator with an LED light attachment to demonstrate the concept… Read More

On Monday, 10/13/25, we presented our PDR to our GE Aerospace liaisons in Cincinnati, Ohio. We had a great day on-site, starting at 8:00 AM. Our presentation was met with insightful discussions and helpful questions. We were given great tours… Read More

This week we presented our preliminary design report (PDR) to three other IPPD groups, coaches, and staff. This was a great opportunity for our team to display our hard work and receive constructive feedback. Constructive questions from the audience are… Read More

The team faced a significant problem that they had to address this week. We contacted the supplier of the high temperature thermoelectric generator (TEG) we were interested in acquiring and found out it is no longer being produced. Fortunately, we… Read More

This week the team met to discuss different ways we could address our scope of work. At the team meeting, each member presented one (or more) ideas that could be used as solutions to the problem of waste heat. Through… Read More

This week, FLARE met on 9/15/2025 to work on our Product Design Specifications (PDS). This is an important document that transforms customer wants and needs into requirements and specifications. We made sure to draft specifications that can be measured by… Read More

We’d like to introduce our team’s name and logo, FLARE: flight level aerothermal recovery of energy. This acronym is a reference to the pyrotechnic device of the same name and symbolizes the energetic qualities of our project. The color scheme… Read More

Hello everyone, welcome to our IPPD blog! We are Team 09, sponsored by GE Aerospace and coached by Dr. Bruce Carroll. Our mission is to develop a waste heat recovery system for hypersonic propulsion.  This week we introduced ourselves, met… Read More