Innovative Manufacturing Processes

This three-phase program will develop a new concept of satellite and payload mounting, structural interface, release and separation motion. A large single satellite mount will be evaluated together with a set of small satellites and scientific payloads.The payloads will be attached and locked to a composite plate structure, fabricated from a composite isogrid core with lightweight carbon fiber skins. Rotary or radial finger locking systems will be considered and electro mechanical and shape memory alloyactuators will comprise the release and separation mechanisms. Shape memory actuators are commercially available. The external aerodynamic fairing will also be analyzed and designed. This design will be an isogrid core with carbon fiber composite skins.The fairing will have a segmental design to enable separation and release. Designs for structural test panels and subscale satellite systems will be prepared. Manufacturing methods will be selected for fabrication of test articles and a full-scaledemonstration unit during Phase II. The designs will match the full range of available U.S. Air Force launch vehicles and deactivated ICBMs. The payload mounting structure and the stage fairing will have the capability of mounting maneuvering andattitude control propulsion systems. Power supplies and stabilization/orientation systems will also be considered. Benefits to the government will be that the system is adaptable to the new low cost launch vehicles, which use deactivated ICBMs. Thesystem will have significant structural payload capability and will utilize structural mounting systems, which do not involve explosive or squib actuated payload separation systems. This proposed system will also design the separation and removal of thepayload fairing system. A lightweight system will permit reduction in overall weight of the payload and payload fairing stage or alternatively will enable additional payloads to be carried. The unit will be adaptable to small micro-satellites currentlybeing launched by government and universities and also for small space experiments. In addition a single large satellite of the 2,000lb class will be considered. A low cost manufacturing method will be used. Risk mitigation will be satisfied by thisprogram by the design of test systems and demonstration articles during the proposed Phase II program. The use of shape memory release devices will provide a reliable low cost method of separation and release of small payload experiments. The use of thissystem design will enable the Air Force to launch its own satellite systems without having to use capacity of the NASA Space Shuttle.