A Comprehensive Design Journey: HyperX Full-Flow Staged Combustion Engine from Concept to 3D Model

Dinesh Appavoo • 2026

Abstract

This paper presents a comprehensive design journey for developing a Full-Flow Staged Combustion (FFSC) rocket engine from fundamental concepts to detailed 3D modeling. The FFSC cycle represents one of the most efficient rocket engine architectures, utilizing both fuel-rich and oxidizer-rich preburners to drive turbopumps while achieving optimal propellant combustion. We detail the complete engineering process including thermodynamic cycle analysis, turbopump design, combustion chamber optimization, nozzle geometry, cooling system architecture, and structural integration. The resulting HyperX engine design demonstrates the feasibility of FFSC implementation with modern computational tools and 3D modeling techniques, providing a reference architecture for next-generation reusable launch vehicles.