Utilizing Additive Manufacturing of Semi-Crystalline Thermoplastics and Topology Optimized Generative Designs for Complex Small Satellite Bus Geometries

Utilizing Additive Manufacturing of Semi-Crystalline Thermoplastics and Topology Optimized Generative Designs for Complex Small Satellite Bus Geometries

Utah State University, Logan, UT

Small satellite buses have traditionally been manufactured through subtractive means and ultimately limiting capability in feature, form, and an inability to alter the volumetric density of the material. However, emergent additive manufacturing methods that utilize Fused Deposition Modeling (FDM) integrated with soluble support material allow us to print synthetic thermoplastics, such as Polyetheretherketone (PEEK). Consequently, the number of structural parts and hardware components is reduced, along with the cost. Structural strength and dimensional stability of PEEK are comparable to traditional aluminum alloys in the construction of most satellite components. Additive manufacturing further allows the implementation of topology optimization algorithms to develop and produce complex geometries with resolutions up to 5μm in x/y movements and 1μm in z movements. Thermoplastics possess ideal strength to weight ratios and thermal expansion coefficients that can be exploited to design more desirable components of small satellite buses. We believe that topology-optimized, 3D-printed small satellite frames made from PEEK can offer a lighter alternative to their metal alloy counterparts. To show this, we will demonstrate the generative optimization of the SPectral Ocean Color (SPOC) satellite’s 3U frame and compare its structural, thermal, and modal analysis simulations to those of an optimized design.