Improving efficiency in CubeSat mass production: A modular and standardized approach

Advancements in CubeSat technologies are revolutionizing space research and commercial satellite applications, enabling CubeSats to conduct advanced, complex missions. A key development is the deployment of CubeSat constellations for continuous monitoring, driven by private space firms due to low costs and scalability. As demand for CubeSat constellations grows, standardized design and development processes are crucial for mass production. Traditional CubeSat interfaces, using a stacking arrangement, increase assembly time and costs due to a lack of standardization. Customizing interfaces for specific missions complicates testing and repairs, reducing reliability and flexibility. System complexity in satellite development causes inefficiency, yet the impact on mass CubeSat production remains unassessed, with no established methods to evaluate satellite assembly complexity. To address these issues, this study investigates CubeSat platform interfaces using industrial design tools like design for manufacturing and assembly and advanced complexity analysis. The goal is to develop a modular, flexible platform with a standardized interface to enhance compatibility and reduce costs. This study describes the development and interface standardization process of a 1U structure platform using a slot-type mechanical interface and a backplane-board-type electrical interface for efficient mass production. The concept, previously demonstrated on a 3U CubeSat, employs a unique method for mounting internal subsystems onto the main structural frame, facilitating integration while minimizing structural parts. Important design parameters influencing efficiency are evaluated against conventional designs for suitability in high-demand applications. Evaluation methods are validated with assembly and disassembly tests, resulting in reduced integration time, lower costs, and improved reliability. Assembly tests and environmental testing under launch conditions have shown promising results, ensuring the design can withstand launch loads.