CubeSat nanosatellites take additive manufacturing to new heights.
Additive manufacturing (AM) is constantly achieving new heights, thanks in no small part to collaboration between academia and industry. Today, an exciting new collaboration between the University of Colorado Boulder and Roboze takes AM one step higher and into the ionosphere.
CubeSats, a type of nanosatellite, are roughly the size of a Rubik’s cube and used for everything from space exploration and monitoring to providing telecommunication services here on Earth. CubeSats have emerged in recent years as a cheaper, quicker and more efficient alternative to larger satellites due to the steady miniaturization of space technology. They often remain operational in space for several months.
The University of Colorado Boulder has launched 10 CubeSats thus far, with 12 more currently in development. Many of these were developed by the Lightning, Atmosphere, Ionosphere and Radiation Belt (LAIR) research group, whose primary objective is to study the effect of lightning and thunderstorms on the “near-Earth space environment.” A lightning strike emits powerful radiation and an electromagnetic pulse powerful enough to be measured on the opposite side of Earth. Because of this, lightning influences the ionosphere, a region of Earth’s atmosphere with a large number of electrically charged particles. Lightning, and its interaction with the ionosphere, can have a tremendous influence on power transmission and radio waves.
LAIR is developing a CubeSat that will spend at least six months in orbit. It will measure electromagnetic waves emitted by lightning discharges on Earth while enduring the harsh conditions of space. Subject to strict size and weight restrictions, this CubeSat has to be designed meticulously. It needs every edge modern science can give.
To meet these restrictions, LAIR is turning to Roboze, which specializes in AM for extreme end-use applications. With its unmatched ability to create complex internal geometries, AM is uniquely positioned to create CubeSat components that satisfy the required strength-to-mass ratio.
“Because we are so constrained by mass, 3D printing was the ideal solution for our CubeSat,” said Vicki Knoer, project researcher. “Roboze allowed us to meet the requirements of the project by guiding us in choosing the most suitable material and in the optimization of the parts to minimize mass. We are very satisfied with the results we are achieving.”
Indeed, material selection is a sizeable part of the challenge. To survive the harsh conditions of space, components must deliver both mechanical and chemical superiority. Roboze has additively manufactured high-performance components across several industries to giants, such as Airbus and Bosch, so it is no stranger to tight tolerances and grueling work environments. For this project, it intends to leverage its high-performance polymer, polyether ether ketone (PEEK), to produce the CubeSat’s magnetic field sensor holders. PEEK, Roboze asserts, combines excellent mechanical characteristics and chemical resistance to thrive in conditions in which even metals cannot deliver, such as food processing, oil and gas, and electronics sectors.
“Thanks to extraordinary mechanical properties as well as high thermal and chemical resistance, 3D printing is rapidly replacing metal in a wide variety of extreme end-use applications including aerospace, mobility and energy,” said Alessio Lorusso, Roboze founder and CEO. “It was an honor and a real privilege to collaborate with the LAIR group on this project. They are one of the pioneers in the use of additive technology in this field, and giving our support to the realization of their mission makes me extremely proud.”
This CubeSat is slated to launch in the first half of 2022.
