One Piece

grabcad

This design solution revolves around a cube-shaped satellite comprised of six identical parts, each containing a sheet metal and two bending extrusions on either side. Additive manufacturing technology guarantees the required stiffness while offering more precision than sheet metal and less material usage compared to CNC methods. Key requirements considered include designing thinner components for ease of machining, enabling the frame to support most force and torque, and positioning extrusions for polishing purposes. The design boasts three major advantages. Firstly, modular construction simplifies manufacturing and assembly processes, significantly reducing time-to-market for emergency situations like environmental monitoring after natural disasters. Secondly, thinner components lead to shorter printing times and improved structural integrity. Thirdly, the frame takes most of the force and torque, thereby reducing material usage in other areas and lowering overall satellite weight. No patent applications have been filed for this design. Selective Laser Sintering (SLS) will be employed due to its cost-effectiveness and ability to print multiple parts simultaneously. The chosen build material is AlSi10Mg, offering excellent thermal properties and minimal weight, which are crucial considerations for satellite construction.