The CubeSat Challenge called for a small-satellite frame design with additive manufacturing in mind. After more than 200 entries were sent in, a foldable version of the 1U CubeSat called FoldSat submitted by Paolo Minetola bagged first place.
Taking into consideration additive manufacturing, FoldSat minimizes time allotted for manufacturing and supports wise use of material waste. It is composed of two parts, a cover and a base, both of which contain three 1U cube faces and can be produced as one piece since assembly integrates hinges into the lateral faces of the cube. This allows the base and cover to snap into place, allowing them to be connected.
For the FoldSat to be made, the manufacturing process needs to be carried out while the parts are unfolded. After the supporting material is removed, the base and cover's lateral faces will be folded. As such, the cube can be designed to have a cover that rotates down to the base, while the base's lateral faces can snap-fit onto the cover's top face and the cover's lateral faces connects to the base's face. With this snap-fit configuration, the cube can be properly closed and locked, ensuring against accidental opening.
To allow for devices and electronic boards to be mounted on the cube, the FoldSat's base feature rails. One of the lateral faces of the cover can be utilized as well as an access port by folding the face after the cube is opened.
By choosing to produce the FoldSat unfolded, manufacturing time can be reduced by 40 percent while reducing materials needed for support by 30 percent, compared to manufacturing in a non-folded configuration. Additionally, the unfolded configuration maximizes production volume and optimizes 3D nesting, reducing costs.
While the FoldSat essentially follows the 1U cube design, its foldable concept can also be applied to other configurations, like 3U and 6U cubes.
For bagging first place, Minetola will be receiving $2,500 in cash and a Makerbot Replicator and material pack. His design will also be printed by Stratasys Direct Manufacturing using commercial materials while his story will be featured in Stratasys' online communication. Minetola's design will also be making rounds in conferences and trade shows Stratasys will be part of.
Aside from awarding 11 entries top spots, the CubeSat Challenge also recognized certain works with honorable mentions.
