Machining for Space Applications: Ensuring Precision and Reliability

Designing components for space applications is no small feat. These parts must withstand the harsh conditions of space, including cosmic and solar radiation, extreme temperature variations, and the inability to perform quick repairs.

At Penta Precision, we have extensive experience supporting customers in the space industry, ensuring their machined components meet these stringent requirements. In our latest blog, we discuss the challenges of designing a CubeSat, including material selection and coatings.

For the full blog, click here.

The Challenge

Space-bound components, whether part of a conventional satellite or a CubeSat, must be lightweight yet incredibly durable. They house high-end electronics, power systems, and communication links, all of which need to operate flawlessly in space's unforgiving environment. This means designers must navigate numerous challenges to create reliable, high-performance parts.

CubeSats: A Cost-Effective Solution

CubeSats have become a popular choice among our customers due to their modularity and cost-effectiveness. These nanosatellites can range from a single unit (1U) to six units (6U) joined together. Their design allows them to piggyback on larger launch vehicles, reducing launch costs significantly.

Designing a CubeSat

When designing a CubeSat, one of the primary considerations is ensuring it conforms to the dispenser standards, allowing it to be securely released into space at the right moment. This requires precise manufacturing and tight tolerances, a specialty of our CNC machining services. Discussing achievable tolerances with your machining partner and ensuring trust in their capabilities is crucial.

Key Design Features for Space Applications

While each space component may have unique requirements, several common design features are essential across applications:

1. Weight reduction: Optimising weight without compromising functionality is critical. This can be achieved by hollowing out non-critical features and varying wall thickness to balance strength and weight.

2. Strength: Material selection and coatings play a vital role in ensuring strength. Incorporating design features like fillets, chamfers, ribs, and gussets can enhance stiffness and reduce stress points, making the components more resilient.

3. Thermal management: Spacecraft experience significant temperature fluctuations. Including internal channels or fins can aid in heat dissipation or retention. Designs must also accommodate thermal expansion and contraction.

Material Selection for Space Components

Choosing the right material is paramount for space applications. Materials must be radiation-proof, vacuum-proof, capable of withstanding extreme temperatures, and lightweight. Commonly used materials include:

• Aluminium 7075 and 6082T6: Known for their strength-to-weight ratios.
• Titanium Alloys (Ti-6Al-4V or Grade 5): Offer excellent durability and resistance.
• Ceramics: While robust, machining ceramics safely requires specialised equipment due to the potential for toxic dust.

It's worth noting that Aluminium 6061, often mentioned in space applications, is similar to Aluminium 6082 but harder to source and more expensive in the UK. Therefore, Aluminium 6082 is recommended for cost-effective performance.

Coatings for Space Components

Beyond material selection, protective coatings are essential. Coatings can enhance conductivity, manage temperature fluctuations, and prevent corrosion. Common practices include:

• Clear Anodising: Provides a protective, corrosion-resistant outer layer.
• Post-Anodising Machining: Ensures necessary electrical conductivity and compatibility with FIP gaskets.
• Iridite Coating: Offers additional corrosion protection without affecting gasket seals.

Next Steps

For those designing CubeSats or other space components, partnering with a trusted machining provider is crucial. At Penta Precision, we offer top-rated CNC machining services and a Design for Manufacture service to help you create the most effective product efficiently. Our experienced team is ready to discuss your project and ensure your components meet the highest standards required for space applications.

For a no-obligation chat about your project, contact us at 023 9266 8334 or email [email protected].

You can read the full blog on our website here.