P20332: Sandia Rocket Payload Cable Tester


Project Summary Project Information

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A Rocket Payload Cable Tester provides an automated method to verify the functionality of electrical cables for custom aerospace systems. This device reduces staff workload by automating data collection and result documentation for specific performance requirements, and improving test repeatability over current methods. The device will make use of Sandia’s chosen connectors, come with an effective calibration method to certify its results, and operate without any wireless connection devices to protect the confidential data. Current cable testing methods are tedious to complete by hand, especially when cables are ordered in bulk. Current methods do not support the dynamic and mixed needs of Saudia’s HOT Shot team.

The goal of this project is to analyze Sandia’s current cable testing methods and develop an automated method that addresses data collection needs while reducing test time. The device will be configurable for various data collection needs, automatically document test results, and provide an indication of test success of failure. The expected end result is a functional prototype that can be configured to suit the HOT Shot team’s changing needs and requirements. The resulting design and prototype needs to use chosen connectors from Sandia, come with a documented calibration method and certification of results, and address security concerns. Design documents and a technical paper for the device are also expected to be provided.

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Project Name
Sandia Rocket Payload Cable Tester
Project Number
Project Family
Automated System and Controls
Start Term
End Term
Faculty Guide
Don Pophal
Primary Customer
Nick Leathe, Sandia National Laboratory

Team Members

From Left to Right: Anthony, Olivia, Mohammed, Drew, and Josh

From Left to Right: Anthony, Olivia, Mohammed, Drew, and Josh

Member Role Contact
Anthony D. Pacaro III Mechanical Designs, Project Manager adp3214@rit.edu
Josh Saltsman Electrical Designs, Purchaser jws8813@rit.edu
Drew Flickinger Electrical Designs, Facilitator dsf7386@rit.edu
Olivia Breglia Mechanical Designs, Lead Engineer, Communicator orb1143@rit.edu
Mohammed Ali Software Designs, Confluence Reviser mra7072@rit.edu

Work Breakdown: By Phase


Planning & Execution

Project Photos and Videos

Imagine RIT

Gate Reviews

Problem Definition

Systems Design

Preliminary Detailed Design

Detailed Design

Build & Test Prep

Subsystem Build & Test

Integrated System Build & Test

Customer Handoff & Final Project Documentation (Verification & Validation)

Work Breakdown: By Topic

Project Management Design Tools Design Documentation Implementation Validation Presentation & Dissemination





Risk Management

Problem Management

Communication & Minutes

Use Cases


Functional Decomposition

Morphological Chart

Pugh Concept Selection


Mechanical Drawings

Electrical Schematics

Software Diagrams

Facility Layout



Test Fixtures


Test Plans

Analysis Results


Test Results

Design Review Documents

Technical Paper


Imagine RIT Exhibit


We want to thank our sponsor and customer, Sandia National Laboratories, our primary customer Nick Leathe, and our guide Don Pophal for helping us through this amazing project.