Angelos Tsinas 15th Annual USU Conference on Small Satellites 1 SSC01-IV-5 Efficient Satellite Structural Design Optimised for Volume Production

In the past, the limited number and production volume of satellites has meant that their structural design has been essentially a one-off procedure. As a result, the most common choice of primary structural medium has been metal. Although eminently reliable and highly proven, this option has led to a comparatively high structural mass fraction of 20-24%. The emergence of communications satellite constellations creates the need for a complete reappraisal of current design practices. Emphasis needs to be given in the implementation of volume production methods, already matured through experience in the aviation industry, to manufacture of satellites. The prospect of new materials and technology can offer reductions in the overall structural mass of satellites in the region of 15-20 % which in turn can lead to significant overall mass savings and reduced launched costs. However the aim of mass reduction can only be appreciated in terms of total cost savings, i.e. the net balance of the mass savings versus the technological application cost should be positive. This paper describes current approaches to the design of volume production satellites such as Technological Islands, Virtual Factory, Multifunctional Surfaces, Short Accelerated Production of Satellites (SNAPSAT) in respect of efficiency and economy. The implementation of volume production methods such as JIT and Taguchi in the area of satellite technology is also examined. Alternative designs for mass production satellite structures are considered. Ideas described include a conventional truss of both composite and aluminium manufacture and a corrugated plate modelled upon the multifunctional surface