ETD

• composite
• cubesat
• sandwich panel
• satellite structure
• solar panel

In the framework of the EXCITE project, an IOD/IOV CubeSat mission, this thesis presents an innovative hybrid-composite structure. The objective is to optimize payload mass availability by designing a lightweight structure capable of enduring launch phase. The proposed solution features a primary frame made of an Aluminium alloy, complemented by a secondary structure manufactured from carbon-fiber composite material for the lateral panels and mounting plates. Additionally, an internal arrangement of the spacecraft components was defined to ensure structural compatibility and integration feasibility. Structural integrity was verified under the envelope of launch environments derived from candidate launch vehicles. A Finite Element Analysis was conducted using Ansys, encompassing Quasi-Static, Modal, Sinusoidal Vibration, Random Vibration, and Shock analyses. Stress results were evaluated against allowable limits to determine critical failure indices. Specifically, the composite material failure index was computed using the Tsai-Wu criterion, yielding maximum indices below the critical threshold, indicating a failure safe design. In accordance with ECSS, the Margins of Safety (MoS) were computed. The results showed positive MoS across all load cases, demonstrating that the structure successfully withstands the ultimate limit loads of the launch phase and complies with mission requirements, achieving a 16% mass reduction compared to standard metallic designs.