Dual Frame CubeSat

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The CubeSat comprises a dual frame system, where two frames are interlocked to provide a lightweight yet strong structure that can endure the forces and temperatures it will face. The design is simple yet effective, featuring only four main parts in the primary assembly. These components can be 3D printed using additive manufacturing for the PEI inner frame and laser sintering for the outer titanium frame. The frames fit together seamlessly with minimal screws required. Circuit board assemblies slide into the inner frame, which is secured by four screws, followed by the enclosure of the outer frame with another four screws. Lastly, solar panels or exterior walls are fastened in place, further strengthening the structure. The inner frame can be customized to accommodate specific PCB layouts, while the outer frame remains consistent. Preliminary FEA studies demonstrate the frame assembly's capacity to withstand 20G loads along each orthogonal axis without significant stress or displacement. With a high safety factor and natural frequencies far from potential interference sources, this CubeSat design offers a robust and lightweight solution for space applications. The materials chosen, titanium and PEI plastic, provide strength and durability while minimizing weight and maintaining structural integrity across temperature variations.