CubeSat designers are increasingly looking to incorporate delicate structures and optics into their payloads. These delicate payloads, however, may not survive the required absolute-worst-case launch vibration testing needed for flight certification. To help address this problem, and to better match testing conditions to real-world launch environments, this thesis introduces Sync, a compact 1/4U CubeSat payload designed to collect data on the vibrations and thermal environments CubeSats experience inside a deployer on the way to orbit. This data can be used to better understand the launch environment for different vehicles, and help develop new, more realistic testing guidelines that could enable more delicate payloads to be launched.

Current trends in spacecraft are leading to smaller, more inexpensive options whenever possible. This shift has been primarily pursued for the opportunity to open a new frontier for technologies with a small financial obligation. Limited power, processing, pointing, and communication capabilities are all common issues which must be considered when miniaturizing systems and implementing low-cost components. This thesis addresses some of these concerns by applying two methods, in attitude estimation and control. Additionally, these methods are not restricted to only small, inexpensive satellites, but offer a benefit to large-scale spacecraft as well. First, star cameras are examined for the tendency to generate streaked star images during maneuvers. This issue also comes into play when pointing capabilities and camera hardware quality are low, as is often the case in small, budget-constrained spacecraft. When pointing capabilities are low, small residual velocities can cause movement of the stars in the focal plane during an exposure, causing them to streak across the image. Additionally, if the camera quality is low, longer exposures may be required to gather sufficient light from a star, further contributing to streaking. Rather than improving the pointing or hardware directly, an algorithm is presented to retrieve and utilize the endpoints of streaked stars to provide feedback where traditional methods do not. This allows precise attitude and angular rate estimates to be derived from an image which, with traditional methods, would return large attitude and rate error. Simulation results are presented which demonstrate endpoint error of approximately half a pixel and rate estimates within 2% of the true angular velocity. Three methods are also considered to remove overlapping star streaks and resident space objects from images to improve performance of both attitude and rate estimates. Results from a large-scale Monte Carlo simulation are presented in order to characterize the performance of the method. iii Additionally, a rapid optimal attitude guidance method is experimentally validated in a groundbased, pico-scale satellite test bed. Fast slewing performance is demonstrated for an incremental step maneuver with low average power consumption. Though the focus of this thesis is primarily on increasing the capabilities of small, inexpensive spacecraft, the methods discussed have the potential to increase the capabilities of current and future large-scale missions as well.

A conceptual dust detection mission, KnightSat III, using pico-scale satellites is analyzed. The purpose of the proposed KnightSat III mission is to aid in the determination of the size, mass, distribution, and number of dust particles in low earth orbits through a low cost and flexible satellite or a formation of satellites equipped with a new dust detector. The analysis of a single satellite mission with an on-board dust detector is described; though this analysis can easily be extended to a formation of pico-scale satellites. Many design aspects of the mission are discussed, including orbit analysis, power management, attitude determination and control, and mass and power budgets. Two of them are emphasized. The first is a new attitude guidance and control method, and the second is the online optimal power scheduling. It is expected that the measurements obtained from this possible future mission will provide insight into the dynamical processes of inner solar system dust, as well as aid in designing proper micro-meteoroid impact mitigation strategies for future man-made spacecraft.

CubeSats, specially the 6U standard, is nowadays the tendency where many developers point towards. The upscaling size of the standard and payloads entail the increase of the satellite overall mass. Composite materials have demonstrated the ability to fulfill expectations like reducing structural masses, having been applied to different types of spacecraft, including small satellites. This Thesis is focused on designing, manufacturing, and dynamic testing of a 6U CubeSat made of carbon fiber, fiberglass, and aluminum. The main objective of this study was obtaining a mass reduction of a 6U CubeSat structure, maintaining the stiffness and strength. Considering the thermal effects of the used materials an outgassing test of the used materials was performed and the experimental results are presented. The CubeSat structure was entirely manufactured and tested at Cal Poly Aerospace Engineering Department facilities. A mechanical shock test and random vibration test were performed using a shock table and a shake table respectively. Results of both tests are presented. A correlation between the Experimental data and the Finite Element Model of the satellite was carried out. Finally, a comparison between 6U structure studied and aluminum 6U structures available in the market is presented.

CubeSat satellites have redefined the standard solution for conducting missions in space due to their unique form factor and cost. The harsh environment of space necessitates examining features that improve satellite robustness and ultimately extend lifetime, which is typical and vital for mission success. The CubeSat development team at Cal Poly, PolySat, has recently redefined its standard avionics platform to support more complex mission capabilities with this robustness in mind. A significant addition was the integration of the Linux operating system, which provides the flexibility to develop much more elaborate protection mechanisms within software, such as support for remote on-orbit software updates. This thesis details the design and development of such a feature-set with critical software recovery and multiple-mission single-CubeSat functionality in mind. As a result, features that focus on software update usability, validation, system recovery, upset tolerance, and extensibility have been developed. These include backup Linux kernel and file system image availability, image validation prior to boot, and the use of multiple file system devices to protect against system upsets. Furthermore, each feature has been designed for usability on current and future missions.

Since their conception in 1999, CubeSats have come and gone a long way. The first few that went into space were more of a “proof of concept,” and were more focused on sending simple data and photographs back to Earth. Since then, vast improvements have been made by over 40 universities and private firms, and now CubeSats are beginning to look towards interplanetary travel. These small satellites could provide a cost effective means of exploring the galaxy, using off the shelf components and piggy-backing on other launch vehicles with more expensive payloads. However, CubeSats are traditionally launched into Low Earth Orbit (LEO), and if an interplanetary satellite is to go anywhere from there, it will need a propulsion system. This thesis project’s main goal will be to investigate the possibility and capability of an Ion-Spray propulsion system. Several problems are to be tackled in this project: how to take a 9 V supply and boost it to a maximum potential difference of 5,000 V, all while minimizing the noise and testing the feasibility of such a system being flown on board a CubeSat.

Currently, the CubeSat spacecraft is predominantly used for missions at Low- Earth Orbit (LEO). There are various limitations to expanding past that range, one of the major ones being the lack of sufficient radiation shielding on the Poly-Picosatellite Orbital Deployer (P-POD). The P-POD attaches to a launch vehicle transporting a primary spacecraft and takes the CubeSats out into their orbit. As the demand for interplanetary exploration grows, there is an equal increase in interest in sending CubeSats further out past their current regime. In a collaboration with NASA’s Jet Propulsion Laboratory (JPL), students from the Cal Poly CubeSat program worked on a preliminary design of an interplanetary CubeSat deployer, the Poly-Picosatellite Deep Space Deployer (PDSD). Radiation concerns were mitigated in a very basic manner, by simply increasing the thickness of the deployer wall panels. While this provided a preliminary idea for improved radiation shielding, full analysis was not conducted to determine what changes to the current P-POD are necessary to make it sufficiently radiation hardened for interplanetary travel. This thesis develops a tool that can be used to further analyze the radiation environment concerns that come up with interplanetary travel. This tool is the connection between any geometry modeled in CAD software and the radiation tool OLTARIS (On- Page iv Line Tool for the Assessment of Radiation In Space). It reads in the CAD file and converts it into MATLAB, at which point it can then perform ray-tracing analysis to get a thickness distribution at any user-defined target points. This thickness distribution file is uploaded to OLTARIS for radiation analysis of the user geometry. To demonstrate the effectiveness of the tool, the radiation environment that a CubeSat sees inside of the current P-POD is characterized to create a radiation map that CubeSat developers can use to better design their satellites. Cases were run to determine the radiation in a low altitude orbit compared to a high altitude orbit, as well as a Europa mission. For the LEO trajectory, doses were seen at levels of 102 mGy, while the GEO trajectory showed results at one order of magnitude lower. Electronics inside the P-POD can survive these doses with the current design, confirming that Earth orbits are safe for CubeSats. The Europa- Jovian Tour mission showed results on a higher scale of 107 mGy, which is too high for electronics in the P-POD. Additional cases at double the original thickness and 100 times the original thickness resulted in dose levels at orders of about 107 and 104 mGy respectively. This gives a scale to work off for a “worst case” scenario and provides a path forward to modifying the shielding on deployers for interplanetary missions. Further analysis is required since increasing the existing P-POD thickness by 100 times is unfeasible from both size and mass perspectives. Ultimately, the end result is that the current P-POD standard does not work too far outside of Earth orbits. Radiation-based changes in the design, materials, and overall shielding of the P- POD need to be made before CubeSats can feasibly perform interplanetary missions.

A vibration model was developed for CubeSats inside the Poly-Picosatellite Orbital Deployer (P-POD). CubeSats are fixed in the Z axis of deployers, and therefore resonate with deployer peaks. CubeSats generally start fixed in the X and Y axes, and then settle into an isolated position. CubeSats do not resonate with deployers after settling into an isolated position. Experimental data shows that the P-POD amplifies vibration loads when CubeSats are fixed in the deployer, and vibration loads are reduced when the CubeSats settle into an isolated position. A concept for a future deployer was proposed that isolates CubeSats from the deployer at the rail interface using viscoelastic foam sandwiched in the deployer rails. By creating an isolator frequency far below the deployer resonant frequency, CubeSats loads are not amplified at the deployer’s resonant peak. Feasibility tests show that CubeSat vibration loads can be reduced to 50% of the vibration input in certain cases. Testing also shows that it is much easier to define vibration loads for isolated CubeSats than CubeSats in the current P-POD.

As science instruments on CubeSats become more sensitive to the attitude of the spacecraft, better methods must be employed to provide the accuracy needed to complete the planned mission. While systems that provide the accuracy required are available commercially, these solutions are not cost-effective, do not allow the design to be tailored to a specific mission, and most importantly, do not give students hand-on experience with attitude control actuators. This thesis documents the design, modeling, and simulation of a low-cost, student-fabricated, reaction wheel system for use in 3U CubeSat satellites. The entire design process for the development of this reaction wheel is based on fundamental design principles and can be replicated for either larger or smaller spacecraft as needed. Additionally, plans for bringing this design up to a prototyping and testing phase are outlined for continued use of this design in the Cal Poly CubeSat Laboratory.

The research presented provides an overview of a 1U+ form factor propulsion system design developed for the Cal Poly CubeSat Laboratory (CPCL). This design utilizes a Radiofrequency Electrothermal Thruster (RFET) called Pocket Rocket that can generate 9.30 m/s of delta-V with argon, and 20.2 ± 3 m/s of delta-V with xenon. Due to the demand for advanced mission capabilities in the CubeSat form factor, a need for micro-propulsion systems that can generate between 1 – 1500 m/s of delta-V are necessary. By 2019, Pocket Rocket had been developed to a Technology Readiness Level (TRL) of 5 and ground tested in a 1U CubeSat form factor that incorporated propellant storage, pressure regulation, RF power and thruster control, as well as two Pocket Rocket thrusters under vacuum, and showcased a thrust of 2.4 mN at a required 10 Wdc of power with Argon propellant. The design focused on ground testing of the thruster and did not incorporate all necessary components for operation of the thruster. Therefore in 2020, a 1U+ Propulsion Module that incorporates Pocket Rocket, the RF amplification PCB, a propellant tank, propellant regulation and delivery, as well as a DC-RF conversion with a PIB, that are all attached to a 2U customer CubeSat for a 3U+ overall form factor. This design was created to increase the TRL level of Pocket Rocket from 5 to 8 by demonstrating drag compensation in a 400 km orbit with a delta-V of 20 ± 3 m/s in the flight configuration. The 1U+ Propulsion Module design included interface and requirements definition, assembly instructions, Concept of Operations (ConOps), as well as structural and thermal analysis of the system. The 1U+ design enhances the capabilities of Pocket Rocket in a 1U+ form factor propulsion system and increases future mission capabilities as well as propulsion system heritage for the CPCL.