The GSLV LVM3, India’s most powerful launch vehicle, is designed to deliver heavy payloads into Geostationary Transfer Orbit (GTO) and beyond. This project focuses on optimizing its second stage by replacing the current L110 hypergolic stage with the advanced SC160 semi-cryogenic stage, powered by ISROsen and liquid oxygen (LOX). The SC160 offers higher thrust, improved specific impulse, and eco-friendly operation. The study includes theoretical analysis of powered ascent, drag and gravity losses, gravity-turn trajectory shaping, and numerical optimization using GPOPS-II. Structural redesigns of tanks, interstages, and thrust frames are incorporated to support cryogenic operations and higher loads. Results indicate a 20–25% increase in specific impulse, 500–800 kg gain in payload capacity, and reduced propellant toxicity. Overall, the SC160 upgrade enhances mission efficiency, payload capability, and environmental sustainability, strengthening GSLV LVM3’s role in future commercial, strategic, and interplanetary missions.

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