Rapid Manufactured Thermoplastic Satellite Structure for QB50 Mission

Satellite structures are conventionally constructed of aerospace-grade metallic and composite [1] materials which can be costly to manufacture and operate. Recent advances in rapid manufacture capabilities now allow this application to satellite structures. Satellite structures constructed using rapid manufacture techniques may be more cost effective, be able to incorporate previously impossible structural complexity and allow optimised structures to be developed that reduce mass, reduce component count and increase functionality. [2] There has been a steady progression of increased resolution, increased speed of production, reduction of unit costs and a widening of material choices in rapid manufacturing. By utilizing 3-D printing techniques, load optimised structures with fewer joints and parts can be manufactured which allow the production of low mass geometries currently not feasible. This research aims to develop, deploy and demonstrate the technology of a satellite structure for a Cube-Satellite utilising rapid manufacturing processes. The CubeSat will be launched as part of the QB50 project which will deploy a network 50 CubeSats into a 'string-of-pearls' configuration to perform atmospheric sounding in the thermosphere. [3]The primary impact of this work is as a proof of concept and technology demonstration. Currently, rapid manufactured satellite structures have a technology readiness level (TRL) of 2-6 depending on the material. The technology has been demonstrated in a laboratory environment, and validated in operational environments. This project aims to carry the development through prototyping in an operational environment (TRL6-7), qualification testing (TRL8) to deployment as a system through mission operations (TRL9). The material has undergone materials selection testing according to ECSS-Q-ST-70-02 (R07), of which Poly-Ether-Ether-Ketone (PEEK) was selected. The selection process incorporated thermal vacuum cycling which monitored the Total Mass Loss (TML) and Collected Volatile Condensable Material (CVCM). In addition, structural assessments before and after thermal vacuum conditioning were performed, where the tensile strength, Young'smodulus, hardness and coefficient of thermal expansion were determined.An initial structural design utilising the selected material has been developed after satisfying preliminary calculations and numerical vibrational analyses via ABAQUS. Material coupon testing, thermal bake-out and outgassing tests have also been performed. After ground testing, a flight ready version of the structure will be manufactured and incorporated into UNSW's QB50 CubeSat. Throughout the life in orbit, material temperature will be monitored along with tensile and Young's modulus. Data will be telemetered to ground and flight data will be used to assess the material and the suitability of the manufacturing process to produce satellite structures and determine the final TRL. 1. "Satellite Structures." ESA - Structures - Satellite Structures. European Space Agency, 31 July 2007. Web. 27 Oct. 2013. http://www.esa.int/TEC/Structures/SEMKYEWUP4F_0.html 2. Foschino, Evan. "The Advantages of 3D Printing | Caliper." Caliper The Advantages of 3D Printing Comments. Caliper Media. Web. 27 Oct. 2013. http://calipermedia.com/theadvantages-of-3d-printing/3. "QB50 Project." QB50 Project. European 7th Framework Programme, 2013. Web.27 Oct. 2013. https://www.qb50.e