PICKA, M. Návrh 3D tištěné CubeSat struktury pro misi KOSTKA [online]. Brno: Vysoké učení technické v Brně. Fakulta elektrotechniky a komunikačních technologií. 2024.
The diploma thesis titled "Design of 3D Printed CubeSat Structure for Mission KOSTKA" focuses on creating a 3D-printed structural frame for a CubeSat. The goal is to improve the frame's strength, reduce its weight, and meet aerospace standards. The thesis details the design process using advanced 3D printing technologies like Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS). The design was improved through simulations to find and fix stress points, enhancing load distribution and material use. Tests confirmed the CubeSat frame's strength under simulated launch conditions. A prototype was successfully 3D-printed using an FDM printer, showing that single-piece production with minimal support material is feasible. Future production with a metal 3D printer is expected to meet precise standards. Key tests included: - Finite Element Analysis (FEA): This showed the frame's initial natural frequency was 400Hz, much higher than the required 100Hz, ensuring it can handle vibrations. The assembled CubeSat had an even higher frequency of about 700Hz, due to the added stiffness from the radiator. - Quasi-static and Random Vibration Testing: These tests found that the highest stress points were around the PCB connections and the THS attachments to the radiator. The stress levels did not cause any plastic deformation, confirming the design's strength. Displacement values were within safe limits, ensuring no major deformation or risk to the structure. The use of metal 3D printing created strong, flexible components, minimizing material use without compromising strength. The final structure met all requirements for the KOSTKA mission, including those set by the launch provider. Marek Picka's thesis successfully tackles the challenges of designing a 3D-printed CubeSat structure. The validated frame under simulated conditions shows the potential of 3D printing for space applications, marking a significant advancement in CubeSat development and providing a solid foundation for future missions.
The thesis titled "Design of 3D Printed CubeSat Structure for Mission KOSTKA" by Bc. Marek Picka is a well-done and detailed study about creating a 3D printed frame for the KOSTKA CubeSat mission. The document is organized, starting with an introduction to CubeSats and 3D printing technologies, and then moving into the practical parts of designing, printing, and testing the frame. A major strength of this thesis is how clearly it states its goals and the step-by-step process taken to reach them. The author provides a thorough introduction to CubeSats, giving a solid background for understanding the design challenges and needs. The choice to use advanced 3D printing techniques, such as Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS), is well-explained, highlighting their benefits in making lightweight and strong components. The design process is impressive because it is iterative, meaning the author kept improving the design by running simulations to find and fix weak spots. This shows a deep understanding of engineering principles and a practical approach to achieving the best performance under real-world conditions. The successful tests of the CubeSat frame prove the design meets the strict requirements of the launch provider and mission goals. Additionally, the thesis provides useful insights into the feasibility of using 3D printing for satellite structures. The discussion about the benefits and challenges of 3D printing, including material properties and post-processing needs, adds valuable depth. This makes the thesis not just a project report but also a helpful reference for future projects in small satellite development. Questions for the Author: 1. Economic Viability: How does the cost of using SLM and DMLS for the CubeSat structure compare to traditional manufacturing methods? Can you provide a cost-benefit analysis that includes production time, material costs, and potential savings in launch costs due to reduced weight? 2. Material Properties: You mentioned the use of AlSi10Mg alloy in your 3D printing process. How does this material's performance compare to other potential alloys that could be used for CubeSat structures? Were there any specific reasons for choosing AlSi10Mg over other options? 3. Environmental Impact: Have you considered the environmental impact of the additive manufacturing process used in your project? Specifically, how do the energy consumption and material waste of SLM and DMLS compare to traditional manufacturing techniques? 4. Post-Processing Requirements: What specific challenges did you encounter during the post-processing phase of the 3D printed CubeSat structure? How did you address issues related to surface roughness and dimensional accuracy? 5. Future Applications: Based on your experience with this project, what are the key considerations for future CubeSat missions looking to adopt 3D printing technologies? Are there any particular design guidelines or best practices you would recommend? Overall,this thesis makes a significant contribution to the field of small satellite development, especially in using 3D printing for CubeSat structures. The study is comprehensive and offers practical insights, making it valuable for both academic and professional audiences.
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