From Structure to System: Multifunctional 3D-Printed Satellite Architectures

Additive manufacturing offers significant potential for the development of highly integrated and cost-effective satellite structures. This research aims to evaluate the viability of monolithic 3D-printed satellite structures for space applications, with a focus on integrating mechanical supports, electrical routing, and electronic functionalities directly into the primary structure. By leveraging the monolithic nature of additive manufacturing, structural elements such as brackets and supports are printed as part of the structure itself, reducing part count (such as bolts or screws), and assembly complexity.

The methodology involves the design and fabrication of multiple structural prototypes, followed by numerical analyses to assess mechanical behavior and structural integrity. In parallel, experimental integration tests are conducted to evaluate mechanical compatibility, electrical functionality, and interface robustness. Two electrical integration approaches are investigated: embedding cables within internal structural channels to reduce integration complexity and embedding printed circuit boards or conductive paths within the structure to partially or fully replace traditional cabling.

The expected outcomes include a validated assessment of the mechanical and electrical performance of multifunctional 3D-printed structures, identification of key design trade-offs, and guidelines for future implementations. The results of this work are directly applicable to CubeSats and other small satellite platforms, enabling more compact, robust, and scalable spacecraft architectures.