Rapid Manufacturing of Multi-functional Satellite Panels with Embedded Components Using Ultrasonic Consolidation

A Phase II collaborative effort between MicroSat Systems, Inc. -- a manufacturer of high performance small satellites -- and Utah State University -- a University with significant advanced satellite manufacturing expertise -- is proposed. The focus of this effort is to take the next step toward a qualified process, and produce flight-worthy, multi-functional structural panels with embedded components using ultrasonic consolidation technology. This will build on the success of our Phase I SBIR effort, where we demonstrated the feasibility of embedding thermal features, including heaters, temperature sensors and heat pipes, in an Al 3003 alloy panel using ultrasonic consolidation. Our Phase II effort will focus on the development of a process and procedure for creating Al 6061 alloy components with embedded functionality that will meet the spacecraft mechanical, thermal and electrical requirements of the Microsatellite Target System and the Plug and Play Satellite. The successful completion of this project will result in a validated process for rapidly manufacturing multi-functional satellite panels for the responsive space community, built at lower production cost, with less labor, and in a matter of days, all while maintaining, and likely increasing, satellite capabilities.