Ever since the revolutionary CubeSat form factor took hold in the Aerospace industry, there has been a desire to send them further and further into space. This thesis introduces an optimization approach to deployment that explores new possibilities of interplanetary CubeSats. In this approach there are three categories of objective functions that are defined by the type of trajectory of a “primary” spacecraft, which carries the CubeSat deployer. These categories are flyby, orbiter, and lander. For each category the objective function starts with four design variables. These are the ΔV of the deployer broken up into three component directions and the true anomaly at the time of deployment. The method then calculates the mission specific objective to be minimized and uses Matlab®’s built in gradient-based optimizer, fmincon. The results show that in the flyby category, the CubeSat has a significantly different turning angle than the primary. The CubeSat can even flyby on the opposite side of the planet. In the orbiter case it is shown that the method works by testing it with two objective functions, the difference in inclination and the difference in eccentricity between the primary and the CubeSat. It is shown that the inclination can be changed by 0.1314° and the eccentricity can be changed by 0.0033. These values, although low in magnitude, are an order of magnitude greater than non-optimal deployment scenarios. Still, another optimization method is introduced to find out how much extra ΔV the CubeSat would need to reach a desired change. This shows that with just an extra 75 m/s of ΔV, the CubeSat can change its orbit by 5°. This could come from either a propulsion system or a modified deployer. The final category, lander, used the flight path angle when entering the atmosphere as an objective. The method shows that flight path angle can be changed by 2.6°. Overall, these examples have proven that the method can find optimal solutions to CubeSat deployment scenarios at other planets.

The Poly-Picosatellite Orbital Deployer (P-POD) has undergone a series of revisions over the years. The latest revision, described in this Master’s Thesis, incorporates new capabilities like EMI shielding, an inert gas purge system, and an electrical interface to the CubeSats after they are integrated into the P-POD. Additionally, some mass reduction modifications are made to the P-POD, while its overall strength is increased. The P-POD inert gas purge system successfully flew, on a previous revision P-POD. The P-POD components are analyzed to a set of dynamic loads for qualification, and successfully undergoes random vibration qualification testing. The P-POD encounters some problems in thermal vacuum cycling qualification and EMI testing, but there is evidence that the issues can be mitigated. A path forward is laid out to complete both sets of testing.

On February 13, 2012, California Polytechnic State University, San Luis Obispo flew three Poly-Picosatellite Orbital Deployers (P-PODs), carrying seven European University CubeSats sponsored by the European Space Agency (ESA), on the Vega Maiden Flight. This was the first time CubeSats shared a ride to space with other payloads on an ESA-owned launch opportunity. In order to meet launch requirements, it must be proven through proper documentation that the P-POD would operate properly and not interfere with the launch vehicle or other payloads on the mission. This thesis outlines the program flow, required documentation, and issues encountered during the launch campaign to get the P-PODs properly qualified and integrated on to the Vega launch vehicle. This mission required Cal Poly to create several unique solutions, which were only implemented for this mission, in order to meet unique technical requirements and programmatic goals. As a result of this mission’s success the ESA Education Office implemented the Fly Your Satellite Program, which has continued to support and launch CubeSats developed by European universities.

The Naval Postgraduate School is currently developing their first CubeSat, the Solar Cell Array Tester CubeSat, or NPS-SCAT. Launching a CubeSat, such as NPS-SCAT, requires environmental testing to ensure not only the success of the mission, but also the safety of other CubeSats housed in the same deployer. This thesis will address the development of CubeSat vibration testing methodology at NPS, including subsystem testing, engineering unit qualification, and flight unit testing. In addition, the new Cal Poly CubeSat Test POD Mk III will be introduced and evaluated based upon comparison with the Poly Picosatellite Orbital Deployer (P-POD). Using examples from the development of NPS-SCAT and test data from Cal Poly’s Test POD Mk III and P-POD, the current CubeSat testing methodology will be verified and an improved method for NPS CubeSat subsystem testing will be presented.

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.