Ground Support Fixture Design
Project Overview
Engineering Design Services completed the design and analysis of specialized ground support and transport fixtures used for handling and moving launch vehicle components across multiple facilities. The project focused on creating robust, flight-compatible transport solutions that protect sensitive aerospace structures during integration, testing, logistics, and marine-based transport operations.
Result & Impact
• Delivered six custom roll ring transport fixtures and one static transport saddle
• Ensured safe handling and transport of sensitive launch vehicle components across multiple environments
• Verified structural integrity through detailed FEA under lifting and transport loads
• Improved operational safety during integration, testing, and logistics activities
• Developed comprehensive fabrication and testing requirements to ensure field reliability
• Enabled durable performance in corrosive marine transport conditions
• Supported compliance with stringent aerospace and client-specific engineering standards
Engineering Tools & Technologies
• Finite Element Analysis (FEA)
• 3D CAD mechanical design and modeling
• Aerospace structural design methodologies
• Lifting and rigging load analysis
• Marine corrosion-resistant material selection
• NASA standards compliance (e.g., GSFC-STD-8009, NASA-STD-5005)
• Manufacturing and quality assurance specification development
• Structural testing and proof load validation procedures
Scope
• Design six unique roll ring transport fixtures
• Design one static transport saddle for launch vehicle components
• Develop interfaces compatible with flight hardware without causing structural damage
• Support breakover operations using double crane picks or integrated tooling systems
• Ensure compatibility with integration, testing, and logistics workflows
• Incorporate marine transport requirements and corrosive environment considerations
• Perform structural verification using finite element analysis (FEA)
• Validate designs against aerospace and client-specific standards (including NASA requirements)
• Develop manufacturing, inspection, and testing requirements
• Define lift point testing, static load testing, weld inspection, and proof load procedures
Solution
Engineering Design Services engineered a fully integrated transport fixture system combining roll rings and a static saddle to safely support launch vehicle segments throughout handling and transportation. Each component was designed to interface directly with flight hardware while distributing loads to prevent damage during lifting and transit. Finite element analysis was used to validate structural performance under all anticipated load cases, ensuring compliance with stringent aerospace safety requirements. The design also incorporated corrosion-resistant materials and construction practices suitable for marine transport environments.
