Qualification of Composite Structure for Cubesat Picosatellites as a Demonstration for Small Satellite Elements

The present work describes the design, structural analysis, and qualification by analysis and experimental validation of the 1st Greek cube-satellite developed at the University of Patras (UPSat - University of Patras Satellite). The key innovative approach includes the replacement of the aluminum parts of the primary structure with structural composite components, something that has never been attempted in the past by other mission following such an approach. A Single-Unit (1U) CubeSat structure made entirely of composite materials was designed, analyzed, manufactured and tested. A comparison with the state-of-the-art, commercially available, structure made out of aluminum (CubeSat-kit) already certified for space use also took place. The work was performed under the vision to prove the feasibility of manufacturing and certifying the structure for space use in the near future. Finite element analysis, confirmed by testing of a 1U Cube Sat, is used to examine trade-offs for the materials and layups. Based on these analyses, recommendations are given for a viable design solution. Results have shown that the redesign of the structure using CFRP can offer similar levels of performance in terms of stiffness while reducing mass by approximately 40%.