Abstract:

Propulsion system testing constitutes one of the most important stages in the development process of experimental sounding rockets. Although test campaigns generate additional infrastructure and operational costs, they enable the validation of propulsion system performance, reduction of engineering uncertainty, and optimization of rocket design parameters. This paper presents selected theoretical and practical aspects of sounding rocket propulsion system testing, including measurement methods for thrust, pressure, temperature, and propellant mass, as well as selected solutions implemented in the propulsion system test stand developed by the student research group PWr In Space.

The study focuses on the technical and economic impact of propulsion system testing on sounding rocket development. Particular attention is given to the influence of experimental validation on the optimization of structural mass, propellant mass, subsystem reliability, and manufacturing processes. The paper presents selected case studies related to injector plate redesign, structural mass optimization using FEM analysis, and hybrid rocket fuel grain manufacturing optimization. The presented examples demonstrate that experimental testing enables the identification of design flaws and the implementation of improvements that may not be achievable using theoretical analysis alone.

The conducted analysis indicates that propulsion system testing may significantly reduce the overall cost of sounding rocket missions despite the additional expenses associated with test campaigns. Reduction of unnecessary propellant mass, optimization of structural components, and improvement of subsystem reliability contribute to increased mission efficiency and reduction of the probability of launch failure. The presented results demonstrate that propulsion system testing should be treated not only as a validation procedure, but also as an important engineering and economic optimization tool in the development of experimental sounding rockets.