CubeSat – SkeletonSat

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The SkeletonSat is a scalable, multipurpose, research satellite designed to work with the current CubeSat deployment system. The 1U unit can be deployed by itself, or scaled up to 2U, 3U, 6U, or even 12U systems. The use of Stratasys DMLS allows for each 1U SkeletonSat to be manufactured as a single part, cutting down on tooling and production costs. I have selected Aluminum AlSi10Mg as it provides high strength, good thermal properties, and good corrosion resistance. It also maintains excellent machinability after being manufactured. Standoffs for connecting multiple units together can be manufactured with Nylon 12 PA using Stratasys SLS. This allows the standoffs to weigh less while maintaining strength. The SkeletonSat has series of mounting points on all of its exterior faces, and have identical patterns on the Z and X faces for modular components. These mounting holes can be either drilled out for clearance or tapped for M2 machine screws. Multiple 1U SkeletonSat attach together with machine screws and standoffs to create 3U systems, which can then attach with machine screws to become a 6U system. As well as for system expansion, these mounting holes allow for a wide variety of internal and external components to be mounted using custom 3D printed brackets. The very open design also means wire routing and access between units is quick and easy. The 1U SkeletonSat weighs a mere 115 grams while a 3U systems with hardware weighs only 357 grams, less than 9 percent of the 4.0 kg limit for a 3U CubeSat. SkeletonSat 3U Total Part Count: 3x SkeletonSat 12x M2 Machine Screws 12x Standoffs