Integrated CubeSat

The CubeSat structure consists of just 3 parts - two structure halves and one screw. With these 3 parts the CubeSat accomplishes structural integrity, offers attachment points for internal printed circuit boards (PCBs), provides an access port panel and incorporates the antenna deployment module into the design. Due to its simple design, the PCBs and sensors inside the CubeSat can be readily accessed by removing only one screw and sliding the CubeSat apart. Structural integrity is guaranteed by hooks and teeth that are part of the structure and that slide into each other. One screw holds the two structures in place. The design is stiff and robust against vibration. The two structural halves are printed using direct metal laser sintering with Aluminium 6061. The material conforms to the CubeSat standard and direct metal laser sintering provides the precision needed to manufacture the parts. Two antenna pairs are available that provide two frequency capability (for up- and downlink for example). Before launch, the antennas are wrapped around the CubeSat in the depression around its circumference. Once in space, a release mechanism (for example cutting of a holding string) is activated and the tape-spring antennas unfold into the position shown in the model. To electronically isolate the antennas from the structure, antenna liners are designed that are 3D plastic printed by selective laser sintering and hold the antennas in the structure. ABS plastic can be used for the liners due to its electric insulation properties. The internal PCBs are stacked on top of each other guided by four metal rods at their corners. Proper PCB separation is ensured using selective laser sintered plastic spacers that slide onto the metal rods between the PCBs. Selective laser sintering is chosen because it offers high precision in the manufacturing process which, in turn, ensures a tight fit of the PCBs providing vibration resilience. The entire PCB-rod stack is placed into holding cups tha