Horizontal EGG Shock Absorbers TPU Cushions for American Rocketry Challenge 2025

GENERAL: 3D file to protect your Eggs in the American Rocketry 2025 Challenge see The American Rocketry Challenge - World's Largest Student Rocket Contest. This year’s ARC challenge has 2 grade A large eggs horizontally mounted in the rocket payload. ARC teams must launch their rocket to the Qualification altitude of 790 feet (241 meters) and recover the payload by parachute within a 41-44 second duration window. See the website link for complete rules, tips, and team handbook. 

DESIGN: 3d file, printed from flexible TPU, or Thermoplastic Polyurethane filament similar to rubber. Many TPU's have a shore rating of ~95. This 2-piece design uses a soft and semi-flexible material that cushions and encapsulates each egg when inserted horizontally into the Large 66mm or 2.6in diameter airframe payload tube. Each egg requires 2 pieces for a total of 4 pieces to be printed for the competition.

I’m providing and making this file available to all teams that are participating in the ARC challenge. TPU is similar to PLA in price, performance and printing characteristics but definitely softer. My tests and launches show that TPU is an ideal material for egg cushions in NAR and NRC competition capsules. I have made this file available for all student teams to download and print at their school, home, or any third-party service for use in the contest.

PRINTING: I used a tiny amount of infill and no top layer but this my preference, The TPU can be stringy but just snip it away. Most TPU's print better on a satin sheet or bed. If using a steel sheet, I've found that a glue stick is beneficial to act as a release agent. A non-stick silicone spatula or similar tool helps as well. The Hatchbox TPU I used was sliced and printed with PLA settings.

QTY: A total of 4 pieces to be printed for the two eggs in the contest-jcieslak