IST Fabrication & Manufacturing Department 

The Fabrication & Manufacturing Department is the physical heart of the Indian Space Team (IST). While the Design Department creates the blueprints, this team is responsible for turning those virtual models into tangible hardware that can withstand the extreme environment of space.

Following your vision of "transforming rural talent into aerospace pioneers," this department often operates with a "hands-on" philosophy, combining industrial precision with the ingenuity of indigenous manufacturing.

Core Responsibilities

The Fabrication & Manufacturing Department manages the transition from computer-aided design (CAD) to the final flight-ready vehicle.

• Engine Fabrication: Specializes in crafting the combustion chambers and nozzle assemblies for the NAMBI Hybrid Engine. This involves high-precision welding and the use of heat-resistant materials.

• Airframe Assembly: Manufacturing the rocket’s "skin" or fuselage. The team works with lightweight composites and aluminum alloys to build the cylindrical stages of the rocket.

• Material Processing: Handling the casting and curing of Solid Fuel Grains (like HTPB) and the integration of liquid oxidizer tanks.

• Prototyping & Iteration: Before a final model is built, this department creates "mock-ups" or structural test articles (STAs) to check for fitment and assembly issues.

Specialized Manufacturing Techniques

As of 2026, the department has shifted toward more advanced, localized manufacturing methods to keep costs low while maintaining high quality:

1. Composite Winding

For high-pressure tanks and rocket bodies, the team utilizes filament winding techniques. This creates structures that are incredibly strong but weigh significantly less than traditional steel or heavy alloys.

2. Precision Machining

Using CNC (Computer Numerical Control) machines, the department produces critical components like Injectors and Valves. In a hybrid engine, the injector's precision is what determines how efficiently the liquid oxidizer interacts with the solid fuel.

3. Quality Control (QC) & Testing

Every part manufactured undergoes rigorous "Non-Destructive Testing" (NDT). This includes pressure testing tanks to ensure they don't leak and X-raying welds to check for microscopic cracks that could cause a failure during launch.

Integration with the "Space Tutor" Mission

Because IST is an official ISRO Space Tutor, the Fabrication & Manufacturing Department serves a dual purpose:

1. Production: Building the hardware for IST’s private aerospace goals.

2. Education: Serving as a "living lab" where students and enthusiasts can see how a rocket is actually put together, bridging the gap between textbook theory and real-world engineering.

The Fabrication Challenge: In rocketry, a mistake of even 0.1mm in a nozzle's diameter can lead to a loss of thrust or an explosion. This department maintains the "Zero-Defect" culture necessary for spaceflight.