Case Study: Hypersonix Launch Systems

Hypersonix Launch Systems engaged M2T Solutions to provide independent explosive hazard analysis for a high pressure hydrogen fuel system used in hypersonic vehicle testing at Carole Park, Brisbane. As a commercial client outside the Defence sector, Hypersonix needed specialist engineering analysis of the risks involved in testing a carbon overwound pressure vessel fuel system, so operators could understand and manage the safety implications of their testing program with confidence.

Testing a high pressure hydrogen fuel system carries real risks of rupture or explosion, with the potential for blast overpressure and high speed fragmentation. Hypersonix needed a structured, defensible way to identify these risks, understand their likelihood and consequence, and put appropriate controls in place, without an existing internal framework for assessing hazards of this kind on a hypersonic vehicle testing program.

M2T Solutions applied bow tie analysis across the credible rupture and explosion scenarios, Gurney models for fragmentation assessment and established blast overpressure methodology, referenced against the relevant Defence explosive ordnance standard and international military standards. We developed a structured list of potential scenarios rated by likelihood and consequence, and built a hazard log using Defence Hazard Risk Management methodology, giving Hypersonix a documented, auditable basis for their risk decisions.

Our analysis calculated specific blast overpressure and fragmentation hazard zones, enabling Hypersonix to determine appropriate exclusion distances and barrier requirements, along with practical recommendations to reduce the severity of each risk. This engagement was delivered as independent technical advisory using established engineering methods, rather than formal Defence explosive ordnance compliance certification, giving Hypersonix expert guidance appropriate to a commercial testing program while keeping the scope of our advice clear.