Structural Electronics Quasi-Additive-Manufacturing (SEQAM)

Tethers Unlimited Inc (TUI) proposes to develop the “Structural Electronics Quasi-Additive-Manufacturing� (SEQAM) Process, a novel approach to building highly-integrated multifunctional systems based upon using standard Printed Circuit Board (PCB) materials as a primary structural medium. The motivation for SEQAM is to reduce the cost of producing small satellite constellations, which are currently burdened by conventional practices that are optimized for traditional high-budget, one-off space missions. TUI is familiar with conventional modes of small satellite construction, as well as the state of the art in multi-material 3D printing, and SEQAM is meant to incorporate the best of both approaches while eliminating the biggest practical problems with each. While multi-material 3D printing technologies can produce integrated functional circuits with impressively centralized fabrication processes, the resulting combinations of material properties are inferior to conventional engineering materials. In contrast, industry standard PCB materials can have ideal and well-understood multifunctional properties, both for their normal requirements as electrical circuits, and for satisfying thermal and structural subsystem requirements. The Phase I effort will assess the feasibility of cost reductions via the SEQAM technology through preliminary design methodology, performing a proof-of-concept demonstration, and testing the cost and functional performance of fabricated test hardware.