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PAYLOAD SYSTEMS ENGINEERING

Engineering console

Payload systems lab

Every gram competes with another sensor. Every watt competes with recording time. Explore the hardware, then work through the trade-offs that shape a student-built balloon payload.

Team flight report · Spring 2026
Reported flight maximum82,497ft
External temperature minimum−66.5°C · report narrative
Time to burst~61min · report narrative
High-altitude CO₂ peak939ppm at 77,483 ft

Values follow the supplied Spring 2026 launch-acquired-data presentation. Older raw-record and fitted-altitude analyses remain separate team working materials. View the research figures.

From model to instrument

Design the interfaces, not just the box

CAD rendering of a removable instrument carrier with lattice panels and mounting rails
Fall 2025 · CAD rendering

Removable instrument carrier

The carrier makes mounting and service access visible before fabrication. Compare fastener access, cable routing and instrument clearance as part of a fit review.

Explore the 2025 engineering record →
Physical Geiger-counter circuit board and tube installed in a black printed instrument carrier
Fall 2025 · Hardware photograph

Electronics meet structure

A mounted Geiger board shows the interface between an instrument and its carrier. Mechanical retention, connector access and sensor exposure belong in the same design review.

Inspect more hardware images →
Interactive trade study

What fits. What keeps running.

All starting values are illustrative, editable assumptions—not measured mission data. Set your own mass target and compare an ideal energy budget. This is a design exercise, not a flight-readiness or NASA compliance certification.

Example: 1,200 g of components against a 1,500 g target leaves 300 g. A nominal 7.4 V, 2,600 mAh pack with 70% usable energy supports a constant 4 W load for approximately 3.37 hours. Enable JavaScript to edit the example.

Requirements

Define mission objectives, required sensors, success criteria, data products, and public-release boundaries.

Build

Structure, mass, battery endurance, sensor mounting, insulation, camera retention, SD-card access.

Operate

Weather review, balloon fill, launch roles, APRS tracking, chase plan, recovery, and payload custody.

Publish

Unit consistency, source labels, workbook reconciliation, plots, gallery, and mission report.

Payload architecture

Subsystem Purpose Evidence
Structure Protect avionics and sensors during ascent, descent, and recovery. Mass budget, CAD, photos, drop/fit checks.
Power Keep sensors, GPS, camera, and logger alive in cold conditions. Battery chemistry, current budget, cold test.
Telemetry Track flight path and support recovery. APRS export, timestamps, coordinates.
Science sensors Measure particulate, CO2, temperature, humidity, and count rate. Datasheets, calibration notes, raw workbooks.
Recovery Preserve payload and data integrity after landing. Landing photos, custody notes, card image.
Flight-proven · Fall 2025

Engineering changes that survived recovery

Carbon composite

The revised body was approximately 20% lighter and returned with minimal damage.

Central power

A single battery system powered the Arduino, sensor suite, and two RunCam Thumb 2 cameras.

Sensor recovery

Recovery procedures were formalized after prior missions exposed preventable data-loss risks.

Reproducible code

Git-based versioning and clearer documentation made software changes traceable across the team.

Read the verified 2025 mission record

Flight readiness review

  • Payload mass and line-load inspection.
  • Battery retention, switch position, cold endurance.
  • GPS lock, APRS callsign, clock sync.
  • Sensor apertures, insulation, camera state.
  • Recovery plan, chase communications, landing documentation.

Unit policy

Keep the original figure's source, period, axes and units together. Reported instrument response is not automatically a calibrated environmental measurement. Counts per minute are not radiation dose without an instrument-specific calibration. Preserve particle units as printed and flag unit ambiguity rather than silently converting them.