User:Dpeters

User data

Name	Dylan Peters
Affiliations	Western University
Location	Canada
Nationality
Interests	Open-Source, Composites, Aerospace, Propulsion, Alternative Rock
Email	dpeter45uwoca
Registered	2026

Dylan Peters is studying at Western University in the department of Mechanical and Materials Engineering. He has developed a strong interest in inventive open-source design with real-world applications, particularly as it pertains to mechanical and aerospace engineering. He has tangible experience in the rework and design of composite aircraft. Throughout his undergrad, Dylan served as Chief Engineer of the Western Engineering Rocketry Team, where he directed the design, manufacture, and integration of all manners of subsystems. His capstone design project, a centrifugal casting system for wax-based fuel grains, exemplifies bespoke mechanical and controls system design.

• Centrifugal caster for wax-based fuel grains
• Composite filament winder
• Alt-mill configuration and enclosure

Centrifugal Caster for Wax-Based Fuel Grains

Hybrid rocket engines require reliable and repeatable production of solid fuel grains. Beginning as a final-year capstone project for the MME4499 program in collaboration with WE Rocketry, the project is focused on the design, manufacture, simulation, and testing of a centrifugal casting machine to produce wax-based (paraffin or beeswax) hollow cylindrical fuel grains with minimal defects.

The current iteration of the centrifugal "spin" caster satisfies key project requirements, including:

• Capable of producing quality fuel grains of varying diameters (for 38mm fuel grain: 25.3mm OD; for 98mm fuel grain: 85.7mm OD);
• Can safely operate through a full casting cycle;
• Easy removal and installation of mold between casts;
• Defect-free fuel grain production (no voids, cracks, inclusions, or shrinkage).

Standalone operation is enabled by an embedded motor control system with onboard user interface, data sensors, and safety interlocking. Upon startup, the caster accepts inputs regarding caster, casing, and fuel configurations, which is used to calculate the anticipated casting duration using heat transfer calculations.

Two fuel molds have been developed, both of which equally compatible with the power transmission systems interchangeable interface for end caps. The first configuration implements a commercial aluminum motor casing (flown on Hyperion II (2025)) and custom aluminum end caps. This allows for casting of a full casing's length of fuel material directly to the casing; following solidification of the wax, the casing can be removed from the caster, the end caps can be unscrewed and exchanged for the upper combustion chamber bulkhead and nozzle of the hybrid rocket engine. The second configuration consists of three 3D-printed parts, secured by compression at four points, with two layers of o-rings to prevent leakage. Polypropylene filament was selected for its non-porosity and high temperature resistance, permitting the pouring of molten wax.

Composite Filament Winder

Filament winding of composite materials presents a scalable, low-cost method of repeatably manufacturing hollow composite tubes without requiring arduous manually hand layup techniques. Continuous fibre tow is wound at an angle, typically 45-55°, following a helical winding path about a mandrel. This part is then covered with release fabric, cured at elevated temperature, and demolded once cured.

Using a former capstone project and an open-source example as jumping off-points, a filament winder for 6" diameter tubes up to 1.3m long has been developed. Multiple iterations have been prototyped, experimenting with X-axis control (fibreglass-reinforced belt vs. lead screw), motor power transmission (belt drive with pulleys vs. direct drive with coupler), and numerous tensioning and resin control configurations.

Carbon (CFRP) and glass (GFRP) fibre tow have been wound with thermosetting epoxy-resin matrix and cured under elevated temperature. The result is a thin, rigid, high-strength composite tube. Tests have been conducted using reinforced cardboard and aluminum mandrels, the former offering easy, destructive demolding of tubes, and the latter countering with reusability and consistent inner diameter tolerance. A 3D-printed conical nosecone-like mold has been produced, though as of yet untested.

Future plans for the project include expansion to small-diameter tubes and phenolic-resin wound kraft paper liners.

Alt-mill Configuration and Enclosure

Completed refurbishment of a 2.5-axis CNC router in the FAST lab. Constructed an enclosure from repurposed protective panels to contain chips using repurposed acrylic panels and aluminum extrusions. Modifications to the GRBL post-processor were explored.