Hyperloop Manchester

Side Quest · University of Manchester · 2022–2024

Overview

As Vacuum Capsule Structural Lead for Hyperloop Manchester, I was responsible for the structural integrity analysis and physical fabrication of the passenger capsule’s airlock section — the most mechanically demanding sub-assembly, subject to ~101 kPa differential pressure under operational conditions.

Structural Challenge

The airlock must:

• Withstand full atmospheric pressure differential (1 atm → ~0 mbar vacuum)
• Seal hermetically under cyclic loading (boarding/alighting cycles)
• Minimise mass (target: <12 kg for the full airlock module)
• Integrate with the capsule’s monocoque carbon fibre shell

My Work

FEA & Analysis

• Conducted nonlinear static structural analysis in ANSYS Mechanical for the pressure vessel under 101.325 kPa external loading.
• Identified critical stress concentration regions at the door hinge attachment points — redesigned the bracket geometry to reduce peak von Mises stress by ~38%.
• Validated mesh convergence with a Richardson extrapolation study; final mesh: ~1.8M hex elements.

Fabrication

• Led physical construction of the aluminium 6061-T6 airlock frame, including CNC milling coordination with the university workshop.
• Specified and sourced pneumatic actuator seals (Parker O-ring series) with appropriate Shore-A durometer for low-temperature vacuum performance.
• Designed a custom jig for repeatable alignment of the door sealing face (tolerance: ±0.1 mm).

Outcome

The Hyperloop Manchester capsule was demonstrated at the European Hyperloop Week competition. The structural airlock design passed vacuum-cycling leak tests at 10⁻³ mbar with zero failures across 50 cycles.