Thrust Vector Control Mount in SolidWorks
Design a gimbal that steers a rocket engine — then prove it will hold.
Last reviewed: March 2026Overview
Thrust vector control is the primary attitude control mechanism for launch vehicles during the high-dynamic-pressure phase of ascent, when aerodynamic fins are ineffective. A TVC mount must allow the engine nozzle to deflect ±5–10° in two axes while transmitting the full thrust load into the vehicle structure with minimal compliance (stiffness matters because too much flexibility creates control instability). Designing this mechanism requires integrating kinematics, structural analysis, materials selection, and manufacturing considerations — it is one of the most complete mechanical design exercises available to an undergraduate.
In this project you will design a gimbal ring assembly using SolidWorks parametric CAD, starting from a thrust and weight budget. The gimbal consists of an outer ring, inner ring, pivot pins, and actuator attachment points. You will use SolidWorks Simulation (FEA) to analyse stress and deformation under the critical load cases: maximum thrust (axial), maximum gimbal deflection (combined axial + side load), and launch vibration. Areas exceeding yield are redesigned through geometry changes or material upgrade, and the process is iterated until all safety factors are met.
The project teaches the full mechanical engineering design loop — requirements, concept, detailed CAD, analysis, iteration, and documentation — using the exact tool suite employed by propulsion companies such as Rocket Lab, SpaceX (for heritage designs), Aerojet Rocketdyne, and university rocket teams. A completed TVC design package is a compelling portfolio artefact for any mechanical or aerospace engineering applicant.
What You'll Learn
- ✓ Translate thrust and deflection requirements into a gimbal geometry concept and preliminary sizing
- ✓ Create a fully parametric SolidWorks assembly with mates that allow motion simulation of gimbal deflection
- ✓ Set up and run SolidWorks Simulation FEA studies for static thrust, combined loads, and modal analysis
- ✓ Identify and redesign stress concentrations to achieve required structural safety factors
- ✓ Produce engineering drawings, a Bill of Materials, and a formal FEA stress analysis report
Step-by-Step Guide
Define requirements and sketch the concept
Establish the design requirements: engine thrust (e.g., 5 kN), nozzle exit diameter, maximum gimbal angle (±8°), actuation force, and structural safety factor (≥2.0 on yield). Sketch two or three gimbal concepts (crossed-flexure, dual-ring, spherical bearing) and down-select to the dual-ring configuration based on stiffness and manufacturing simplicity. Document the trade-off rationale.
Build the parametric CAD assembly
Model the outer ring, inner ring, four pivot pins, and two linear actuator clevises in SolidWorks using sketch-driven profiles with named global variables (ring diameter, wall thickness, pin diameter). Assemble with concentric and coincident mates that allow the inner ring to rotate on each pivot axis. Run the motion simulation at maximum deflection to confirm there is no part interference throughout the range of motion.
Apply loads and boundary conditions for FEA
Set up a SolidWorks Simulation static study. Fix the outer ring mounting flange. Apply the full thrust force at the nozzle interface point combined with the worst-case lateral force (10% of thrust) that occurs at maximum gimbal deflection. Assign Aluminium 7075-T6 material to all structural parts. Mesh with default settings first, then refine the mesh at pin holes and fillet radii.
Analyse and iterate on high-stress regions
Review the von Mises stress plot and factor of safety contour. Identify regions with FOS < 2.0 — typically pin bores and ring-to-clevis transitions. Increase fillet radii, add gussets, or increase wall thickness as needed. Re-run FEA after each geometric change and record the FOS improvement. Achieve FOS ≥ 2.0 everywhere with minimum mass added.
Run modal analysis and check for resonance
Perform a frequency (modal) study to find the first five natural frequencies of the gimbal assembly. Compare these against the predicted launch vehicle vibration spectrum (typically 20–2000 Hz for acoustic loading). If any mode falls within the excitation band, stiffen the design (increase thickness or add ribs) until the fundamental frequency clears the excitation range by at least 20%.
Produce the design package
Generate fully dimensioned 2D engineering drawings for each part and the assembly, including GD&T for critical pin bores and mating surfaces. Create a Bill of Materials listing material, mass, and procurement specification. Write a formal stress analysis report including load derivation, FEA setup description, stress and FOS plots for each load case, modal results, and a conclusion certifying the design meets all requirements.
Career Connection
See how this project connects to real aerospace careers.
Aerospace Engineer →
Propulsion and structures engineers at launch vehicle companies perform exactly this design-analyse-iterate cycle using SolidWorks or equivalent tools.
Aerospace Manufacturing →
Manufacturing engineers use the same CAD/FEA package to design tooling fixtures and evaluate manufacturing-induced loads on flight hardware.
Avionics Technician →
Avionics technicians mounting equipment to airframes benefit from understanding structural load paths and FEA outputs when assessing installation configurations.
Astronaut →
Astronauts with engineering backgrounds who review vehicle designs benefit from hands-on FEA experience when evaluating structural risk during mission readiness reviews.
Go Further
- Add a topology optimisation study to find the minimum-mass outer ring geometry that still meets FOS requirements, then rebuild the CAD to match the optimised topology.
- Model the two linear actuators explicitly and run a SolidWorks Motion study that simulates a step command, computing actuator forces as the gimbal deflects under thrust load.
- Export the assembly to STEP format and re-analyse in a free FEA tool (e.g., CalculiX via PrePoMax) to verify SolidWorks results.
- Design a 3D-printable version in PETG or ABS and test it on a thrust stand to compare actual deflection stiffness against the FEA prediction.