Dimensional validation of CubeSat structures using 3D optical scanning technology

CubeSat nanosatellites require precise dimensional verification to ensure compatibility with launch systems; however, current validation methods, such as Vernier calipers, are prone to human error and pose risks to satellite systems. This study explores the use of 3D optical scanning technology, specifically MetraSCAN3D, for the dimensional validation of 1U CubeSat structures. For this purpose, five CubeSat models were manufactured using additive processes and evaluated using 3D scanning and conventional methods. To carry out the process, a structured methodology was implemented, comprising preparation, scanning with the MetraSCAN3D, and a Measurement System Analysis (MSA) including Gauge Repeatability and Reproducibility (GRR), bias, and linearity studies. Results showed the MetraSCAN3D reduced GRR variance to as low as 0.93% compared with vernier calipers, significantly improving accuracy and precision while mitigating human-induced variability. This approach enhances reliability in CubeSat dimensional validation and highlights its potential for broader applications in the aerospace industry.