Design and Construction of a One-Piece Multifunctional Small Satellite Bus Structure

This paper describes the design and manufacture of a multifunctional space structure. The analytical techniques used in this project included thermal analyses of structures in various earth orbits, determination of structural requirements from optical performance calculations, designing of near zero Coefficient of Thermal Expansion (CTE) laminates, consideration of manufacturing and material variations in design, strength analysis of composite laminates, determination of vibration modes and associated frequencies of tubular structures with anisotropic sandwich construction walls, and optimization of composite sandwich structures considering all of the above factors. The manufacturing technologies needed to build such a structure were also developed. These technologies included the building of co-cured honeycomb panels, curved panels, core splices, and tubular sections. These efforts culminated in the production of a space-worthy component.