Case Studies US Air Force Optimizes CubeSat using Architected Materials

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	US Air Force Optimizes CubeSat using Architected Materials

US Air Force Optimizes CubeSat using Architected Materials

Technology Category	Analytics & Modeling - Digital Twin / Simulation Analytics & Modeling - Generative AI Other - Additive Manufacturing
Applicable Industries	Aerospace
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Digital Twin Manufacturing System Automation Rapid Prototyping
Services	Software Design & Engineering Services System Integration
Challenge	The U.S. Air Force Institute of Technology (AFIT) faced the challenge of reducing the weight and production time of a CubeSat bus, which traditionally required machining of nearly 150 parts. The conventional design demanded tight tolerances and close quality control, creating 150 potential points of failure. The goal was to develop a structure that fulfills all design requirements and can be manufactured using a repeatable process. Read More
About Customer	The U.S. Air Force Institute of Technology (AFIT) is a premier institution that provides advanced education and research opportunities to military and civilian personnel. AFIT focuses on leveraging cutting-edge technologies to solve complex engineering challenges. In this case, AFIT aimed to optimize the CubeSat bus, a small and relatively inexpensive satellite used for research and communications by government and private agencies. CubeSats enable the concept of ridesharing, allowing multiple satellites to be launched on a single structural chassis, thereby reducing the high cost of sending a payload into orbit. Read More
Solution	AFIT used nTopology's software to leverage architected materials, developing a CubeSat bus assembly from Inconel 718 that was 50% lighter and 20% stiffer than the original aluminum assembly. The R&D team explored multiple thin-walled TMPS and strut-based lattice structures, assessing their performance using engineering simulation. After several iterations, they identified a design with a superior stiffness-to-weight ratio and a lower coefficient of thermal expansion. Using nTopology’s direct-to-manufacture capabilities, the team bypassed the need to generate STL files, creating slices and tool paths directly in the design software. A 3D printed and finished CubeSat was ready for testing in only 3.5 business days. The structural bus was then evaluated and certified according to the NASA GEVS launch profile methodology. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Analytics & Modeling - Generative AI

Other - Additive Manufacturing

Applicable Industries

Aerospace

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Digital Twin

Manufacturing System Automation

Rapid Prototyping

Services

Software Design & Engineering Services

System Integration

Challenge

The U.S. Air Force Institute of Technology (AFIT) faced the challenge of reducing the weight and production time of a CubeSat bus, which traditionally required machining of nearly 150 parts. The conventional design demanded tight tolerances and close quality control, creating 150 potential points of failure. The goal was to develop a structure that fulfills all design requirements and can be manufactured using a repeatable process.

About Customer

The U.S. Air Force Institute of Technology (AFIT) is a premier institution that provides advanced education and research opportunities to military and civilian personnel. AFIT focuses on leveraging cutting-edge technologies to solve complex engineering challenges. In this case, AFIT aimed to optimize the CubeSat bus, a small and relatively inexpensive satellite used for research and communications by government and private agencies. CubeSats enable the concept of ridesharing, allowing multiple satellites to be launched on a single structural chassis, thereby reducing the high cost of sending a payload into orbit.

Solution

AFIT used nTopology's software to leverage architected materials, developing a CubeSat bus assembly from Inconel 718 that was 50% lighter and 20% stiffer than the original aluminum assembly. The R&D team explored multiple thin-walled TMPS and strut-based lattice structures, assessing their performance using engineering simulation. After several iterations, they identified a design with a superior stiffness-to-weight ratio and a lower coefficient of thermal expansion. Using nTopology’s direct-to-manufacture capabilities, the team bypassed the need to generate STL files, creating slices and tool paths directly in the design software. A 3D printed and finished CubeSat was ready for testing in only 3.5 business days. The structural bus was then evaluated and certified according to the NASA GEVS launch profile methodology.

Impact #1	Expedited production: The use of digital workflows significantly cut production times of complex engineering products.
Impact #2	Simplified quality control: Consolidating large assemblies reduced potential points-of-failure and quality control requirements.
Impact #3	Higher-performing products: Leveraging next-generation design and manufacturing technologies resulted in revolutionary products.

Impact #1

Expedited production: The use of digital workflows significantly cut production times of complex engineering products.

Impact #2

Simplified quality control: Consolidating large assemblies reduced potential points-of-failure and quality control requirements.

Impact #3

Higher-performing products: Leveraging next-generation design and manufacturing technologies resulted in revolutionary products.

Benefit #1	50% lighter CubeSat bus assembly.
Benefit #2	20% stiffer than the original aluminum assembly.
Benefit #3	3.5 business days to produce a 3D printed and finished CubeSat.

Benefit #1

50% lighter CubeSat bus assembly.

Benefit #2

20% stiffer than the original aluminum assembly.

Benefit #3

3.5 business days to produce a 3D printed and finished CubeSat.

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Overview

US Air Force Optimizes CubeSat using Architected Materials

Operational Impact

Quantitative Benefit