Designer's Challenge: Josh Kassel Gives the Design2Fly Kit a Hypersonic Edge

With a background in sport rockets and performance rocketry, Estes designer Josh Kassel approached the Design2Fly Challenge with a clear goal: if he could not make his creation fast, he was going to make it look fast.

The result is a hypersonic vehicle inspired by elements of several real-world aircraft. We asked Josh to share the inspiration, creative decisions, and building process behind his original Design2Fly Builder Kit creation.

What inspired the concept for your rocket, and how did that initial idea evolve as you began building?

Most of my background is in sport rockets and performance rocketry, so modeling is somewhat new. If I couldn't make this build fast, then it was definitely going to look fast.

Making it look like a hypersonic vehicle was the goal, and as I went, it took on aspects of many different real-world flight vehicles.

How did the parts included in the Design2Fly Kit influence the shape, features, or overall direction of your design?

The kit had core components, but if I wanted to do something besides a standard rocket, I was going to have to get creative with how I used what was supplied.

With all of the body tubes, I knew I had plenty of material to make engines and intakes. It was just a matter of getting the sizing right to make it aesthetic.

Did any of the parts spark an unexpected idea or lead you in a direction you had not originally planned?

Since I set out to design a hypersonic plane, I wanted a canopy that a pilot could sit in. I took the spare balsa left after cutting my fins and wings, laminated the pieces using wood glue, and hand-sculpted the canopy shape.

I definitely was not planning on doing a laminate, but I think the shape adds to the overall design.

In the same way, the intakes on the underside were part of the original design, but the square shape of the housing was something that I decided to do as I was building it to give the plane more complexity.

Which detail or design choice are you most proud of, and what makes it special to you?

The intakes on the bottom of the plane are something I am proud of.

The idea for the square shape came from the underside of an F-22 Raptor. After some cutting and a lot of sanding, I think the intakes integrate well with the rest of the build while also being striking.

What advice would you give someone opening a Design2Fly Kit and creating a custom rocket for the first time?

Be creative and get outside of your comfort zone. This kit gives you ample material if you need to make changes, but you might surprise yourself with what you come up with.

Speaking from experience, this design pushed me creatively, but I had a blast putting it together. Although the end product is by no means perfect, I am happy with how it came out.

From Concept to Hypersonic Creation

Explore the gallery below for a closer look at Josh’s design and build process, including the hand-sculpted canopy, aircraft-inspired intakes, and other details that shaped his finished creation.

Follow Josh’s build from its early construction stages to the completed hypersonic flight vehicle.

What Will You Create?

The Design2Fly Builder Kit gives you an assortment of rocket parts and the freedom to decide what they become. Take inspiration from Josh’s build, explore your own ideas, and create a rocket that is entirely your own.