Integrated CubeSat

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The CubeSat structure comprises merely three components, including two halves of its structure and one screw. These parts provide structural integrity, attachment points for internal printed circuit boards (PCBs), an access port panel, and integrate the antenna deployment module into the design. Owing to its simplistic design, the PCBs and sensors within the CubeSat can be easily accessed by removing a single screw and separating the structure. Structural integrity is ensured through hooks and teeth integrated into the structure that slide into each other, while the two halves are held together by one screw. The design is robust against vibration and rigid. Both structural halves are manufactured using direct metal laser sintering with Aluminium 6061, adhering to CubeSat standards. Direct metal laser sintering ensures precision necessary for part manufacturing. Two pairs of antennas provide dual-frequency capability (e.g., up- and downlink). Before launch, the antennas are wrapped around the CubeSat within the structure's depression. In space, a release mechanism (for example, cutting a holding string) activates, and tape-spring antennas unfold into their designated positions. Antenna liners, 3D printed by selective laser sintering, electrically isolate the antennas from the structure and hold them in place. ABS plastic can be utilized for these liners due to its insulating properties. The internal PCBs are stacked on top of each other using four metal rods at their corners. Selective laser sintered plastic spacers, ensuring proper separation, slide onto the metal rods between the PCBs. This high-precision manufacturing process provides a tight fit, enhancing vibration resilience. The entire PCB-rod stack is placed into holding cups that are part of the CubeSat structure. Once the two structures are joined, the PCB-rod stack remains firmly fixed and can endure launch vibrations. The design adheres to CubeSat dimensions standards, including rail clearance. A 3-U configuration could be achieved by scaling the design and incorporating additional hooks along the edges for structural integrity. 3D printing offers waste-free manufacturing of all parts, contrasting traditional methods that would require cutting metal cubes to create the two structural parts. Additionally, the high degree of functional integration into structural parts makes them complex and time-consuming to manufacture traditionally.