SM2 - Manufacturing Systems & Processes

Sustainable Satellite ManufacturinG

UKSA Space Cluster Microcredentials

02

Manufacturing Systems & Processes

• Understand the key stages of satellite manufacturing.
• Learn about quality assurance and international standards in satellite manufacturing.
• Explore the differences between traditional satellite manufacturing and new space manufacture of cubesats and smallsats.

Block 2 - Learning Objectives

• Starting from the initial concept to the successful launch, satellite manufacturing is a complex and multi-stage process.
• Manufacturing primarily takes place in phases C&D, however decisions that impact manufacturing occur across the project lifetime.

Key steps in the process are:

1. design
2. material selection
3. build
4. testing
5. launch preparation
• Each stage plays a crucial role in ensuring the satellite's functionality, durability, and success in its mission.
• Stages are iterative and include multiple review stages

Overview of Satellite Manufacturing PRocess

Satellite Design Process

• The design phase is where the foundation of a satellite mission is laid.
• During this stage, various factors and considerations come into play to shape the satellite's specifications and functionality.

Factors to Consider in Satellite Design

• Mission Objectives: Clearly define the mission's goals, such as Earth observation, communication, or scientific research.
• Payload Requirements: Determine the payload's characteristics and instruments needed to achieve mission objectives.
• Orbit Selection: Choose the appropriate orbit for the mission, considering altitude, inclination, and coverage area.
• Power Requirements: Calculate the power needs of the satellite and design solar panels or other power sources accordingly.
• Communications: Decide on communication systems for data transmission to and from the satellite.
• Weight and Size: Strive for an optimal balance between weight and size to meet launch vehicle constraints.

Basics of Design

• Environmental Considerations: Account for the harsh space environment, including radiation, extreme temperatures, and micrometeoroid impacts.

• Redundancy and Reliability: Plan for redundancy in critical systems to ensure mission success.
• Cost Constraints: Adhere to budget constraints while meeting mission objectives.
• Regulatory Compliance: Ensure compliance with international and national space regulations.
• Innovations: Explore innovative technologies and design approaches to improve satellite efficiency and capabilities.
• Sustainability: Consider sustainable practices in materials and manufacturing to reduce the satellite's environmental impact.
• Testing and Validation: Develop a plan for rigorous testing to validate the satellite's design and functionality.
• Integration with Launch Vehicle: Ensure compatibility with the chosen launch vehicle.
• Successful satellite design involves a careful balance of these factors to meet mission objectives while ensuring the satellite's reliability and functionality in the harsh space environment.

Basics of Design (Cont)

The concept of nanosatellites and cubesats emerged in the late 1990s, revolutionizing space exploration with small, cost-effective alternatives to traditional satellites. Cubesats face strict size and weight limitations, challenging engineers to miniaturize components without sacrificing performance. This constraint fosters innovation in small-scale satellite technology. Key advancements include:

• miniaturisation of technology, enabling these compact satellites to perform tasks previously requiring larger satellites.

• the development of standardized deployment systems that allowed cubestats to piggy back on traditional launches
• improved solar cell efficiency
• advanced onboard computing capabilities.

All of these innovations have enhanced communication, navigation, and data collection capabilities.

Development of Nanosats & Cubesats

• The small size and lower cost of cubesats open up space exploration and research to universities, small businesses, and developing countries, democratising access to space.

• Cubesats and nanosats are utilised in a variety of applications ranging from Earth observation and climate monitoring to scientific research and educational purposes. They play a crucial role in testing new space technologies at a lower cost and risk.

• Early missions were demonstrators of key technology:

• QuakeSat aimed at earthquake detection.
• ESTCube-1 demonstrated an innovative propulsion systems using electric solar-wind sail.
• Lunar IceCube mission used an ion thurster.

• Now Nano/CubeSats have a wide variety of applications and can provide real-time data critical for weather forecasting, disaster response, and environmental monitoring.
• Seahawk, built in Scotland focuses on ocean color observation to study ocean biology and its impact on Earth's climate.
• Spire operates a constellation of cubsats to monitor weather patterns, maritime activities, and atmospheric changes, providing critical data for climate research, disaster response, and commercial applications.

Applications of Nanosats & Cubesats

• Power: often rely on smaller, less powerful solar panels and batteries compared to traditional satellites. This limitation affects their operational lifespan and capabilities.
• Communications: utilise compact and efficient communication systems. Innovations in miniaturized communication technology are critical for cubesat functionality.
• Payload: can carry sophisticated payloads for Earth observation, scientific research, and technology demonstration, albeit with less capacity than their larger counterparts.
• Continuous advancements in miniaturisation and efficiency are closing the gap between cubesat and traditional satellite capabilities, particularly in areas like propulsion and onboard data processing.
• As technology advances, cubesats are expected to undertake more complex missions, rivaling traditional satellites in some domains and expanding the scope of cost-effective space exploration and utilisation.

Nanosat/Cubesat Design

• Can be 20 years from concept to launch.
• Target lifetimes 5 to 10 years but often last much longer.
• Suited for complex missions with multiple aims.
• While constrained by size and power they often have significantly more power available.
• Total budget in the 10s to 100s millions depending on the mission.
• Dominated by large-scale, government-funded projects with long development cycles.

Traditional

Cubesats

• Smaller, lighter.
• Very quick to design and build.
• Cheap to build and launch.
• Typical lifetime of 12 to 18 months.
• Suitable for simpler missions with a single purpose.
• Constrained by size and power.
• Total budget can be as low as a few hundred £.
• Focused on smaller, cost-effective satellites (smallsats and cubesats), rapid development, and commercial applications.

Cubsats vs Traditional Design

Build a Cubesat

• Cubesat manufacturing involves streamlined processes tailored for mass production.
• Initial design phases focus on miniaturizing components while optimising functionality.
• Advanced fabrication techniques, such as 3D printing, are increasingly used to produce structural components rapidly and cost-effectively.
• Assembly occurs in cleanroom environments to prevent contamination, emphasising modular design for easier integration and testing.

Cubesat Manufacturing Processes

• Automation plays a crucial role in the cubesat manufacturing process, enhancing precision and efficiency.
• Automated systems are employed for assembling electronic boards, testing communication systems, and verifying power subsystems.
• This shift towards automation not only accelerates production timelines but also ensures consistent quality across multiple units, crucial for deploying large cubesat constellations.

Development of Nanosats & Cubesats

• COTS components have transformed cubesat design and manufacturing by providing accessible, cost-effective components.
• Advantages include
• reduced development times lower expenses, making space missions more viable for smaller organisations.
• access to a wide range of technologies.
• COTS products are typically well-tested and come with reliable documentation, reducing the need for extensive in-house testing.
• However, challenges arise in ensuring these components can withstand the harsh conditions of space remain.
• Balancing the use of COTS with the need for reliability is key to successful cubesat missions.
• Components widely used include
• microcontrollers and computer systems like Arduino and Raspberry Pi for on-board data handling
• GPS modules for positioning
• consumer-grade cameras for Earth observation.
• Communication modules, such as those used in mobile phones, are adapted for satellite communication
• Standard batteries and solar cells are employed for power supply.

USe of Commerical off the Shelf (COTS) Components

Manufacturing efficiencies in the space industry, such as the use of standardised parts, automation, and advanced materials, have significantly reduced costs and production times. This democratises access to space, allowing more entities to participate in space missions. The industry can respond more rapidly to technological advancements and market demands, fostering innovation and making space exploration more accessible and affordable. Efficiency improvements have also led to more sustainable practices, minimizing waste and energy use, this leads on to consideration of sustainable satellite manufacturing

Impact of Manufacturing Efficiencies

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While Cubesats are built by commercial organisations to deliver for profit services they can also be built from readily available parts available on the "high street". This is a fun DIY activity so show how it can be done. The video has a part 2 under the same author

NASA Goddard has developed this short video to explain what a cubesat can do and demonstrate some applications.