Mission SeaLion Integrated CubeSat Design Approach to Accommodate Mission Critical Payloads in a Low Earth Orbit

In the dynamic landscape of space applications, CubeSats have emerged as pivotal platforms for scientific research, technological innovation, and educational endeavors. As the demand for small form factor satellites continues to rise, there is an increasingly critical need for a holistic and rapid development approach in the design of CubeSat structures and payloads. This research focuses on Old Dominion University’s (ODU) integrated design approach of accommodating mission critical payloads in its second space mission, nicknamed Mission SeaLion. The 3U CubeSat class satellite mission is a partnership between ODU, the U.S. Coast Guard Academy (USCGA), and the U.S. Air Force Institute of Technology (AFIT). The goal of Mission SeaLion is to validate on-orbit – (i) an impedance probe, (ii) a commercial-off-the-shelf UHF Doppler payload, and (iii) a deployable composite structure (DeCS) experiment. Mission SeaLion is scheduled to be launched aboard Firefly Aerospace’s small launch vehicle, Alpha, out of Vandenburg Space Force Base in Fall 2024. In development for Mission SeaLion is a novel multi-function drag enhancement and measurement system, which is encapsulated in the DeCS experiment. The integrated design approach to Mission SeaLion’s satellite bus is characterized by its three primary payloads and the need to accommodate a 3-tier communication system including a software defined UHF radio as a Doppler payload, which is aimed at extending the U.S. Coast Guard’s reception of distress calls beyond visual line of sight within the arctic circle. This paper describes the integrated design approach as well as the comprehensive framework utilized to seamlessly integrate peripherals and subsystems within mission space, power, and weight constraints. A significant section of the paper is dedicated to the design of a novel deployment mechanism as a technology enabler for NASA’s in-space assembly and manufacturing program. The paper also describes in detail the design of a sheet-metal based CubeSat structure to accommodate a host of peripherals on the surface. As part of the discussion on the CubeSat structure, the paper also provides an insight into the design of custom configurations of surface mounted and deployable solar panels to ensure adequate power generation despite the absence of an attitude control system.