Throughout the 2025-2026 year, MIT Rocket Team Structures manufactured two full ten foot diameter semi-ellipsoid parachutes as a main. The first parachute was constructed during IAP and spanned around three weeks to get to the point of full connection between all gores. The lines and edgework for the parachute were completed in the weeks following the beginning of the spring semester. Post test launch and the loss of the original parachute, a second parachute was constructed. Two weeks were taken to get to full connection of gores.
Creating gore templates
After sizing of the parachute and gores have been completed using a web application called Parachute Gore DXF Generator, the diagram is projected onto a chalkboard or whiteboard in which a large roll of paper has been taped. Using sharpies the diagram is traced including the seam lines. The template is then cut to the size of just the gore. During the second round of manufacturing we found it time efficient to create an extra template for the purpose of multi-tasking.
Cutting out Gores
The fabric, ripstop nylon 1.1 ounce calendar, should be laid down across multiple tables pushed together, then flattened and reinforced with weights.Once the template is put on top of the fabric, the weights can be moved to the template. Pins facing inward should be placed along the seam lines to secure the template down to the fabric before cutting.
Marking seam lines
The most officiant method for marking seam lines is to tape the template to a window when it is still light outside. The fabric can then be pinned to the template matching perfectly in shape. The sharpie lines on the template should be visible from the fabric allowing them to be traced.
Pinning pairs of gores
The connection points of the gores should be a felled seam. To pin the gores together start by placing the two gores on top of each other with their edges about a quarter inch apart. The bottom gore should be shiny side up and the top shiny side down. Fold the bottom edges over the edge of the top gore to a quarter inch and pin. Then flip the top gore so both gores are facing up, before flipping the whole pair so they are both face down. At this point a second fold should have been created at the seam under the first fold. More pins now perpendicular to the seam should be placed along the edges before the previous pins are removed.
Attaching Seam Tape
The skirt bottoms and vent tops should be secured using nylon seam reinforcement tape. Along the edges tape the shiny side and then fold the taped edge and secure it with clips. Tape both sides of the gore again, this time the tape will cover the already taped folded side + an extra quarter inch.
Sewing Connection Points
Going slow and steady on the sewing machine, a single line is sewn in the middle of the french felled seam with backstitching on both the top and bottom and removing pins as you go. The seams should be the same until reaching the final connection line between gores. For this seam two-three people should be used: one to sew, one-two to hold the extra fabric. Carefully separate the extra fabric away from the machine and slowly run the machine through the connection line while gently pulling the extra fabric.
Attaching and Sewing Webbing
Webbing lines should be cut so that they are longer than the actual gore. There should be multiple inches hanging off the top and button of the gore pairs. The amount hanging off does not need to be specific as there should be excess cut off in later steps. Pin perpendicular to the seam lines the webbing directly on top of the sewn line on the non-shiny side of the parachute. The webbing can then be sewn on both edges of the webbing using backstitching to begin and end.