SMALLSAT LAUNCH ADAPTER STRUCTURE


APPLICATION:

Space launch. Space-X Falcon 9 rideshare payload on May 25, 2022.

PREVIOUS LIMITING TECHNOLOGY:

Older aluminum structures were large, expensive, and heavy. By converting to a composite structure, the customer was able to allot more of their mass budget to orbital payloads rather than the adapter structure.

CHALLENGE:

This is a launch adapter manifold that mounts an array of smallsat deployers to the launch vehicle. Fourteen (14) launchers are arrayed around the octagon and two (2) are mounted on the flat “top” to manifold together for a total of sixteen (16). The challenge was to a create a structure sufficiently stiff to meet minimum natural frequency requirements and shock loads. The orientation and weight of the “top” payload drove much of the structural needs and had to be closely coordinated with the customer. Fabrication challenges related to core shaping meant creating specialty core forming tools, validating, and implementing a new process.

SOLUTION

Rather than using high-cost high modulus composite material, Rock West recommended standard modulus material with published material allowables to create a clear path to launch provider acceptance and cost avoidance.

Closeup image of the top of the octagon section of the smallsat launch adapter structure. There are machined holes, metallic inserts, and rectangular-shaped cutouts showing the core structure with potting material for a smooth finish inside the cutouts. The exterior is a carbon fiber weave with a matte finish. The background is white.
Aspect angle looking at the smallsat launch adapter structural ring. There are machined holes with metallic inserts along the bottom and top flat edges of the ring., The surface is a carbon fiber weave with a matte finish. The ring sits upon a white table with a neutral background.
Image shows the two pieces of the smallsat launch adapter structures in a manufacturing bay. They are sitting on a granite table with a protective white foam layer on its surface. The structural ring is in the foreground and the octagonal structure is behind and to the left of the ring.
Image shows the two pieces of the smallsat launch adapter structure in a manufacturing area and looks down at them from above and to the side. They are sitting on a dark-colored pallette with a protective white foam layer on its surface. The structural ring is to the left and the octagonal structure is on the right.
Image shows the octagonal section of the smallsat launch adapter structure in a manufacturing area and looks down at it from slightly above and to the side. It is sitting on a dark-colored pallette with a protective white foam layer on its surface. The surface is a matte carbon fiber weave. There are metallic inserts, cutouts and drill holes at various junctures.
Image is in a manufacturing area. The launch adapter structure is sitting on a table top. Several surfaces of the octagonal structure have cube-shaped smallsats attached. Six smallsats are visible on the sides of the structure and one is attached to the top. (Image courtesy QuadM)