FoldSat

grabcad

FoldSat is a unique version of the 1U CubeSat that uses additive manufacturing to minimize production time and waste. It consists of two parts: a base and a cover, each having three faces of the cube. They can be produced as single pieces due to their hinge integration for folding lateral faces together with snap fits for connecting the base and cover. To manufacture, keep the parts in an unfolded position, then fold the lateral faces after removing support material. The cover is rotated top-down on the base, connecting the snap fits on both parts. Lateral faces of the base contain rails to mount electronics while one face on the cover can be used as access port. FDM production time can be reduced by 40% compared to folded configuration, with a 30% reduction in support material. Unfolded configuration also allows for optimal 3D nesting and maximizes production volumes, reducing costs. Foldable design can be applied to other CubeSat configurations as well.