Rapid Manufacturing of Reconfigurable Satellite Panels with Embedded Electronics, Embedded Thermal Devices, and Novel Structural Features

The Center for Advanced Satellite Manufacturing (CASM) at Utah State University has been investigating the use of new, advanced manufacturing technologies for the rapid manufacture of highly capable satellite panels. Using Ultrasonic Consolidation it is now possible to additively manufacture (a.k.a. rapid prototype) aluminum structures with embedded electronics, thermal devices, internal structural features, and fibers. CASM has built and tested embedded USB networks, electronic devices, thermal sensors, heat pipes, optical fibers, and other features within aluminum structures to create intelligent, self-monitoring panels for space applications. This work and its potential for providing rapid reconfigurability and rapid manufacturability for Responsive Space purposes will be presented