Design and analysis of aerospace payload Structure

The primary function of aerospace payload structure in aerospace applications is to provide mechanical support and stability to the thruster while withstanding dynamic and thermal loads. These structures must be lightweight yet possess high specific strength and stiffness to ensure optimal performance. Honeycomb sandwich panels are widely used in aerospace payload structure due to their excellent strength-to-weight ratio, fatigue resistance, and energy absorption capabilities. In this study, the design and analysis of aerospace payload structure have been carried out. The model consists of a honeycomb core sandwiched between two Aluminium 2024 sheets, providing high structural integrity. The honeycomb core enhances load distribution and impact resistance, while the aluminium sheets ensure durability and heat dissipation. Additionally, parametric studies were conducted by varying honeycomb thickness, aluminium sheet thickness, and the number of supporting brackets to evaluate their effect on mechanical performance. Finite Element Analysis (FEA) was performed to assess the structural response under different loading conditions. Free vibration analysis was conducted to determine the fundamental natural frequency, ensuring that resonance does not affect structural integrity. Static analysis was performed to evaluate stress distribution and displacement under varying thrust loads. The results provide insights into the optimal configuration for a lightweight and structurally efficient aerospace payload.