Satellite hardware enclosure

ANT61 aims to launch and achieve Beacon M in-orbit qualifications through launches in October 2025 and July 2026. Adhering to standard smallsat sizes and layouts, I developed different enclosures and packaged internal components to interface with Backplane PCBs, PC/104 & Pumpkin Stack, cable connections, and microsatellite compartments. My prototypes were mechanically tested with various customer satellites to ensure smooth fit and ease of operation. A few of these new Beacons were presented at the Colorado Space Symposium, the Australian Space Summit, and the Australian Space Forum in 2024. 

1.  Conducted research on popular CubeSat and MicroSat interfaces, including backplane, PC/104, Pumpkin Stack, and cable connections.

2. Designed enclosure (Fusion 360) in compliance with standard layouts, size, and easy connection with satellite hardware at any location. I adhered to DFM principles for CNC milling, considering corner radius, tool diameter/length, and setup steps.

3. Packaged electronic components, including GNSS and transmitter modules, batteries, and data/RF connectors. The enclosure provided standoffs, mounts, and other supports to prevent stress. I coordinated with the electrical team to place hardware at ideal locations for PCB manufacturing, line loss, and wire tracing. 

4. Performed preliminary stress calculations on enclosure bending under 20g launch load. Since most loads will be applied to the main satellite structure, there were no significant concerns about shear, torsion, or shock. Enclosure vibration and radiation performance will be tested at university labs.

5. Tested integration in CAD with available models from customers or collaborators.

6. 3D printed prototypes to test mechanical fit with electronics, through rods, and fasteners. I made iterations from observations and feedback.

7. Created manufacturing drawings and outsourced for CNC machining.

8. My designs also inspired future models of the Beacon series

9. The team will continue to mature the Beacon product line based on customer feedback, performance tests, and integration assessments (cabling, accessibility, and compatibility) with small satellites.

Interning abroad at a space startup was transformative in many ways. I improved my knowledge of mechanical design, satellite hardware, and communication with audiences from different cultural backgrounds. I'm also grateful for the professional opportunities that ANT61 offered: Beacon's first launch test onboard the MAPHEUS-14 sounding rocket, visits to USYD and UNSW's satellite labs, and the Australian Space Summit. Overall, I became a better, multicultural engineer by tackling challenges and seeing how others do engineering at the home of deep tech in Australia.