Modular Satellite Testing Platform with CFF Printing for Thermal Control
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Solution Overview
Problem
There is a need for a modular satellite testing platform that reduces lead times, weight, and cost while allowing for customization, and addresses the thermal and electrical conductivity challenges of new materials in space environments.
Innovation Solution
A modular satellite testing platform system made using continuous fiber fabrication (CFF) 3D printing with micro-carbon fiber filled nylon composite material, incorporating a thermal control system, multilayer insulation, and thermal coatings, along with a configurable design featuring components such as upper and lower members, support members, hinge members, and a thermal control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional materials like aluminum are used to construct satellite structures, then the satellite achieves reliable thermal and electrical conductivity, but the manufacturing lead time increases and cost increases
Solution Approach 1:
The patent changes the material parameters from traditional metals to composite materials with specific thermal and electrical conductivity properties, allowing for reduced lead times while maintaining reliability through controlled material composition and 3D printing processes
Solution Approach 2:
The patent employs composite materials that combine multiple properties to achieve both reduced weight and acceptable thermal/electrical conductivity, replacing traditional aluminum while maintaining functional requirements through material science innovations
2Strength
If traditional metals are used for satellite construction, then structural strength and thermal response are well understood, but the satellite weight increases and manufacturing complexity increases
Solution Approach 1:
The patent uses composite materials that provide equivalent or superior strength-to-weight ratios compared to traditional metals, reducing satellite weight while maintaining structural integrity through advanced material composition and 3D printed geometry
Solution Approach 2:
The patent segments the satellite structure into modular components printed using 3D printing technology, allowing for optimized weight distribution and reduced overall mass while maintaining strength through computational design and additive manufacturing processes
3Productivity
If new materials are used to reduce weight and lead time, then manufacturing efficiency improves, but thermal control and electrical conductivity become challenging
Solution Approach 1:
The patent adjusts material parameters through 3D printing processes to control thermal and electrical conductivity properties, enabling rapid prototyping and manufacturing while achieving desired thermal management and electrical performance through parameter optimization
Solution Approach 2:
The patent introduces thermal control systems and electrical management components as intermediaries between the new materials and the satellite's functional requirements, ensuring that the inherent properties of new materials can be harnessed while meeting reliability standards through active control systems
4Adaptability or versatility
If modular design is implemented to allow customization, then adaptability improves, but device complexity increases
Solution Approach 1:
The patent divides the satellite into modular segments that can be independently designed, manufactured, and assembled, allowing for customization while reducing complexity through standardized interfaces and 3D printed components that simplify integration
Solution Approach 2:
The patent creates universal modular components that can serve multiple functions and be configured for different satellite missions, increasing adaptability while reducing overall system complexity through multi-functional design and reusable elements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves reduced lead times, lower weight, and cost, while providing thermal regulation and electrical power management, enabling efficient on-orbit testing and data collection.
Implementation Method 1
The modular satellite testing platform may further include hinge members, bottom cover members, shelf members, and a thermal control system
Implementation Method 2
incorporating a thermal control system, multilayer insulation, and thermal coatings
Implementation Method 3
made using continuous fiber fabrication (CFF) 3D printing with micro-carbon fiber filled nylon composite material
Data Source
AI summary
A modular satellite testing platform system having an upper and a lower member along with a plurality of support members, intermediate members, and lower bar members that are interconnected to the upper member and the lower member. The system further includes a plurality of shelf members that are attached to the support members. The satellite also includes a plurality of bottom cover members that are attached to the lower member by a plurality of hinge members that allow the cover members to selectively rotated about an axis to be rotatably translated between an opened position and a closed position. The system yet further includes a thermal control system to allow maintaining the thermals of the satellite as desired.