Launch vehicle design and sizing

Abstract

This work forms part of the lecture material for a 1st year BSc course on aerospace design (AE1222-II) at TU-Delft/faculty of Aerospace Engineering. This document deals specifically with space launch vehicle design and presents the general approach and methods used in conceptual space launch vehicle design in the period from 2010 till present (June 2025). The basic method is structured along 7 steps that represent general steps in solving a (design) problem and includes 1) defining the problem, 2) establishment of requirements, 3) setting up design options, 4) analyzing design options, 5) comparing design options, 6) trading design options and selecting the best option choice, and 7) Evaluating and if necessary iterating on the design. In this document all these steps are described in some detail. Analysis methods described allow to study single stage and multi-stage launch vehicles employing a mix of series and parallel staged vehicles, thereby taking into account different rocket propellants. Also, the fundamentals of optimum staging are discussed and worked out. Aspects tackled in the design next to propulsion include aerodynamics and stable flight, rocket structures (including the effect of tank pressure on stage design), avionics, and onboard electric power systems. Additionally, some simple models are introduced that allow for explaining the fundamentals of reliability and cost estimation. For each of the elements covered examples are provided as to help clarify the methods as well as their usage.