SkyForge: Stratospheric Ozone Systems
Validating ozone generation at -60°C and FL400 altitudes.
Role: CTO & Lead Engineer
Tools: Arduino, SolidWorks Flow Simulation, Ozone Sensors
The Challenge
Developing an ozone restoration payload for aircraft required the system to operate at 10–13 km altitude (Crusing Altitude), where temperatures drop to -60°C and air density is minimal.
The Approach
- Simulation: Before cutting metal, I used SolidWorks Flow Simulation to iterate the housing geometry. The goal was to reduce the velocity of the incoming Mach 0.8 airflow to a laminar flow suitable for stable corona discharge.
- Prototyping: Built a sensor integration testbed using Arduino. Integrated high-sensitivity sensors for Ozone (O3), Flow Rate, Pressure, and Temperature.
- Power: Modified a standard HV power supply to maintain stable arc discharge under varying load conditions.
Fig 1. CFD Aerodynamic Analysis
Fig 2. Mechanical System Layout
Fig 3. Manufactured Prototype
Result
Validated the aerodynamic design and sensor fusion logic. Established the baseline architecture for the "In-Flight Ozone Restoration" concept (Provisional Patent work).