Small Satellite Design for Responsive Manufacturing

The Operationally Responsive Space (ORS) Office is developing a small satellite capability designed specifically for advanced manufacturing and assembly methods for a semi-automated assembly and test facility. Designing a small satellite to be assembled and tested with this novel and innovative approach enables reduced costs, schedule, and risk. In partnership with Millennium Engineering and Integration Company, Raytheon Missile Systems, Applied Minds Inc, and Space Dynamics Laboratory, ORS is developing a 6U modular cubesat as the proof-of-concept article to demonstrate Responsive Manufacturing objectives through three primary thrusts: Open Manufacturing, Digital Assurance, and Responsive Space Parts. This paper will discuss the implementation, design features, lessons learned, and challenges associated with developing for this new rapid-assembly capability as well as the unique benefits and challenges of assembly and test using automated and robotic systems. It will also include discussions of the role that design-for-manufacturing, modular open system architecture, componentized subsystems, and standardized interfaces each played in the development of the spacecraft