Hamed Akhavan, INEGI
João Manuel Cardoso, INEGI
Caio Adler, INEGI
Rúben Emanuel Ferreira, INEGI
João Pedro Alves, INEGI
Hamed Akhavan, Dr, INEGI
This study considers the innovative use of reusable thermoplastic materials as a sustainable alternative to aluminum in the construction of satellite bus structures, aligning with circular economy principles. By integrating thermoplastics into satellite design, the study aims to reduce dependence on traditional metallic components while maintaining the structural integrity required to endure the stresses of launch and orbital environments. Thermoplastics provide unique advantages, such as recyclability and cost-effective manufacturing, achieved through advanced techniques like thermoforming and over-molding. These characteristics make them a compelling choice for addressing both environmental and economic challenges in modern aerospace design.
To assess the feasibility of thermoplastics in this context, a detailed analysis was conducted to understand their impact on satellite subsystems. The study identified specific applications for thermoplastics, particularly as external panels and primary structural components for small satellites. These areas were chosen due to the high potential for weight reduction, improved manufacturability, and end-of-life recyclability. Thermoplastics’ inherent mechanical properties, including their strength, temperature stability, and resistance to atomic oxygen, are well-suited to meet the stringent demands of the space environment.
A critical step in the research was a trade-off analysis to evaluate and select suitable thermoplastic materials. Parameters such as outgassing behavior, chemical resistance, manufacturability, and cost were examined to ensure compatibility with aerospace requirements. This process led to the identification of thermoplastics capable of delivering both performance and sustainability benefits. Following material selection, three structural designs for small satellite bus structures were developed and analyzed using finite element modeling techniques. These simulations included static analysis to assess displacement and stress responses, modal analysis to evaluate natural frequencies, and random vibration analysis to ensure structural resilience under launch conditions. Based on the outcomes, the most promising design was selected for further development.
To validate the design and demonstrate the practical application of thermoplastics, a small-scale mock-up was fabricated using PETG material. This prototype allowed researchers to test key assembly and disassembly processes, providing valuable insights into the practicality of using thermoplastics in satellite manufacturing. The mock-up also highlighted the potential for rapid prototyping and iteration, a significant advantage over traditional manufacturing methods.
The next phase of the research will involve the production of a full-scale demonstrator using the selected thermoplastic material and advanced manufacturing techniques. Thermoforming will play a pivotal role in shaping complex geometries with precision and efficiency, enabling the creation of lightweight, high-performance satellite structures. This demonstrator will serve as a proof of concept, showcasing the viability of thermoplastics in real-world aerospace applications.
Overall, this study underscores the transformative potential of thermoplastics in satellite design. By offering a sustainable, cost-effective alternative to conventional materials, thermoplastics not only meet the rigorous performance standards of the aerospace industry but also contribute to reducing environmental impact. This work represents a significant step toward creating a more sustainable future for satellite development, demonstrating how innovative material choices can drive progress in both engineering and environmental stewardship.