Integrated Aero-Structural Design and Supersonic Flight Validation of a 3D-Printed Composite Rocket Nose Cone

This study presents the complete aero-structural design, additive manufacturing, and experimental flight validation of a rocket nose cone produced via fused deposition modeling (FDM) using PET-G and internally reinforced with a fiberglass–epoxy composite. A tangent ogive geometry (caliber ratio C = 2.21) was selected to ensure aerodynamic efficiency in the Mach 1.2–2.2 regime and was evaluated through high-fidelity CFD simulations under a conservative Mach 2 sea-level scenario, representing the upper bound of aerodynamic loading. Structural performance was assessed using finite element analysis under combined aerodynamic pressure and inertial loads, demonstrating that the hybrid 3D-printed and composite-reinforced configuration provides improved stiffness, reduced deformation, and enhanced stress distribution compared to the unreinforced thermoplastic structure. The nose cone was integrated into a full-scale rocket and validated through a supersonic flight test campaign. The vehicle reached an altitude of approximately 9772 m and a peak Mach number of approximately 1.7–1.8, sustaining supersonic conditions for approximately 11.2 seconds during the early ascent phase. The maximum dynamic pressure, approximately 160–170 kPa, occurred within the first seconds of flight, corresponding to the most critical aero-structural loading regime. These values remain below the conservative CFD predictions, confirming the robustness of the numerical design approach. Post-flight inspection confirmed the complete structural integrity of the nose cone, with no evidence of cracking, delamination, or permanent deformation. The results provide rare full-scale experimental validation of a 3D-printed and composite-reinforced aerodynamic structure operating in a real supersonic environment, demonstrating the feasibility of hybrid additive–composite manufacturing for flight-critical aerospace applications.