Design of a solar panel deployment mechanism for a 6U-CubeSat

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master_Waqar_Talha_2025.pdf (2.85 MB)

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School of Engineering | Master's thesis
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Date

2025-11-18

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Major/Subject

Product Development

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Degree programme

Master's programme in Mechanical Engineering
Konetekniikan maisteriohjelma
Magisterprogrammet i maskinteknik

Language

en

Pages

70

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Abstract

This thesis presents the design and development of a solar panel deployment mechanism for a 6U CubeSat. The aim of the work was to design a cost-effective, reliable, and manufacturable system capable of deploying two stacked solar panels in orbit, using commercial off-the-shelf materials and fabrication methods accessible within a university environment. A detailed literature review was conducted to understand existing deployment technologies, environmental challenges in space, and lessons from previous Aalto University missions. These findings highlighted the need for a simple, passive, and low-cost solution that could meet the structural and environmental constraints of CubeSat missions. A dual tape-spring hinge mechanism was selected and developed as the core deployment concept. The design employs two opposite-sense tape-springs mounted on curved saddles to ensure smooth torque characteristics and high deployed stiffness. The saddles were designed to match the natural curvature of the tape to minimize stress concentration and prevent plastic deformation. A functional prototype was fabricated using acrylic panels and tape-spring elements, demonstrating 180° deployment of both panels. The system was tested for long-term stowage effects, confirming consistent shape retention and reliable deployment after 30 days in the folded state. The results show that the proposed mechanism meets the requirements of simplicity, low cost, and functional reliability, making it suitable for student-driven small satellite projects. Recommendations for future work include miniaturization of the hinge, integration with a Hold and Release Mechanism (HRM), and environmental testing under vibration and thermal-vacuum conditions to advance the design toward flight qualification.

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Supervisor

Kiviluoma, Panu

Thesis advisor

Anger, Marius

Keywords

small satellites, solar array deployment, spacecraft mechanisms, tape-spring hinges, space engineering, passive actuation

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https://urn.fi/URN:NBN:fi:aalto-202512169321

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