Technical Foundations and Lifecycle of CubeSats: From Manufacturing to End of Use

Technical Foundations and Lifecycle of CubeSats: From Manufacturing to End of Use

CubeSats, small modular satellites that have revolutionized space exploration, rely on a variety of advanced technologies and streamlined processes from their design to their operational end. This article delves into the technical infrastructure, manufacturing processes, and the full lifecycle of CubeSats, exploring their launch, orbit dynamics, and eventual decommissioning.

Technical Infrastructure of CubeSats

The technical foundation of CubeSats lies in their modular design, which adheres to a standard unit size of 10x10x10 centimeters (1U). Larger configurations, such as 2U, 3U, or 6U, can be assembled by combining these basic units. The modularity ensures cost-effectiveness and compatibility with a variety of launch vehicles.

Core Components

  1. Structure: The satellite’s frame is typically constructed from lightweight yet durable materials, such as aluminum alloys or carbon composites. These materials are designed to withstand the stresses of launch and provide protection against space radiation and micrometeoroids.
  2. Power System: CubeSats are powered by solar panels that convert sunlight into electrical energy. The energy is stored in rechargeable lithium-ion batteries, which supply power to the satellite’s subsystems during periods when it is in the Earth’s shadow.
  3. Communication System: CubeSats are equipped with antennas and transceivers for establishing a communication link with ground stations. Commonly used frequency bands include UHF, VHF, S-band, and X-band. The communication systems allow telemetry data transmission, command reception, and payload data transfer.
  4. Onboard Computer: The onboard computer (OBC) serves as the brain of the CubeSat, managing its operations and processing data. Modern CubeSats often use low-power microcontrollers or single-board computers, such as Raspberry Pi or CubeSat Kit boards.
  5. Attitude Determination and Control System (ADCS): To ensure proper orientation in space, CubeSats use sensors like gyroscopes, magnetometers, and sun sensors, along with actuators like reaction wheels and magnetorquers. This system is critical for tasks such as Earth observation and maintaining communication alignment.
  6. Payload: The payload varies depending on the mission objectives and may include cameras, spectrometers, sensors, or experimental devices. Payload design is customized to suit specific research, communication, or imaging requirements.

Manufacturing Process

The manufacturing of CubeSats involves several stages, from design to integration:

  1. Design and Simulation: Using CAD software, engineers design the satellite’s structure and components. Simulations are conducted to test thermal performance, structural integrity, and orbital behavior.
  2. Component Procurement: Standardized parts are sourced from suppliers, including solar panels, antennas, and electronic boards. This off-the-shelf approach significantly reduces costs and development time.
  3. Assembly: The CubeSat is assembled in cleanrooms to prevent contamination. Components are integrated into the satellite’s structure, with meticulous attention to wiring and connections.
  4. Testing: Rigorous testing ensures the satellite’s reliability. Thermal vacuum tests simulate the vacuum and temperature extremes of space, while vibration tests replicate launch conditions. Electromagnetic compatibility (EMC) tests ensure the satellite’s systems do not interfere with each other.
  5. Integration with Deployment System: The CubeSat is placed inside a deployer, such as the Poly-Picosatellite Orbital Deployer (P-POD), which protects it during launch and ensures safe deployment into orbit.

Launch and Orbit Deployment

CubeSats are typically launched as secondary payloads aboard larger rockets. This “rideshare” approach minimizes costs by sharing the launch vehicle with other missions.

Launch Equipment

  • Launch Vehicle: Rockets such as SpaceX’s Falcon 9, Rocket Lab’s Electron, and India’s PSLV are commonly used for CubeSat launches.
  • Deployer System: The P-POD or similar deployers ensure the safe release of CubeSats into their designated orbits. These systems use spring-loaded mechanisms to eject the satellite.

Orbit and Movement

CubeSats are often placed in low Earth orbit (LEO), at altitudes ranging from 200 to 1200 kilometers. This orbit is advantageous due to reduced launch costs, lower latency for communication, and easier access for Earth observation.

  • Orbital Maneuvering: Most CubeSats lack propulsion systems, relying on their initial deployment velocity and ADCS for orientation and stabilization. Advanced CubeSats may include miniature propulsion systems, such as cold gas thrusters or ion propulsion, for minor orbital adjustments.
  • Lifespan: The typical operational lifespan of CubeSats ranges from one to five years, depending on mission requirements and orbital decay rates.

End-of-Life Strategies

Once a CubeSat reaches the end of its operational life, it is decommissioned. Strategies for managing defunct CubeSats include:

  1. Natural Orbital Decay: CubeSats in LEO gradually lose altitude due to atmospheric drag and eventually burn up upon reentry into the Earth’s atmosphere.
  2. Controlled Deorbiting: Some CubeSats are equipped with deorbiting devices, such as drag sails, to expedite atmospheric reentry.
  3. Space Debris Mitigation: To comply with international guidelines, CubeSats are designed to minimize the creation of space debris by ensuring complete disintegration during reentry.

Ground Station Communication

The communication between CubeSats and ground stations is managed through specialized hardware and software systems:

  1. Ground Stations: Equipped with antennas, transceivers, and tracking systems, ground stations monitor the satellite’s position and receive data.
  2. Mission Control Software: Open-source platforms like COSMOS and proprietary systems are used to monitor and control CubeSats. These software tools facilitate real-time data visualization, command execution, and telemetry analysis.
  3. Communication Protocols: Data transmission often follows protocols such as AX.25 or CCSDS to ensure reliable communication.

 

The lifecycle of a CubeSat, from manufacturing to decommissioning, showcases the remarkable advancements in miniaturized space technologies. With their modular design, cost-effective manufacturing, and versatile applications, CubeSats have become an indispensable tool for space exploration, research, and communication. As technology continues to evolve, CubeSats are expected to play an even more significant role in expanding humanity’s reach into space.