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US Air Force Optimizes CubeSat using Architected Materials
Technology Category
- Analytics & Modeling - Digital Twin / Simulation
- Analytics & Modeling - Generative AI
- Other - Additive Manufacturing
Applicable Industries
- Aerospace
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Digital Twin
- Manufacturing System Automation
- Rapid Prototyping
Services
- Software Design & Engineering Services
- System Integration
The Challenge
The U.S. Air Force Institute of Technology (AFIT) faced the challenge of reducing the weight and production time of a CubeSat bus, which traditionally required machining of nearly 150 parts. The conventional design demanded tight tolerances and close quality control, creating 150 potential points of failure. The goal was to develop a structure that fulfills all design requirements and can be manufactured using a repeatable process.
About The Customer
The U.S. Air Force Institute of Technology (AFIT) is a premier institution that provides advanced education and research opportunities to military and civilian personnel. AFIT focuses on leveraging cutting-edge technologies to solve complex engineering challenges. In this case, AFIT aimed to optimize the CubeSat bus, a small and relatively inexpensive satellite used for research and communications by government and private agencies. CubeSats enable the concept of ridesharing, allowing multiple satellites to be launched on a single structural chassis, thereby reducing the high cost of sending a payload into orbit.
The Solution
AFIT used nTopology's software to leverage architected materials, developing a CubeSat bus assembly from Inconel 718 that was 50% lighter and 20% stiffer than the original aluminum assembly. The R&D team explored multiple thin-walled TMPS and strut-based lattice structures, assessing their performance using engineering simulation. After several iterations, they identified a design with a superior stiffness-to-weight ratio and a lower coefficient of thermal expansion. Using nTopology’s direct-to-manufacture capabilities, the team bypassed the need to generate STL files, creating slices and tool paths directly in the design software. A 3D printed and finished CubeSat was ready for testing in only 3.5 business days. The structural bus was then evaluated and certified according to the NASA GEVS launch profile methodology.
Operational Impact
Quantitative Benefit
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