P16102: RIT-SPEX Structure

Build & Test Prep

Table of Contents

Week 5 Review Shared Vision

Test Plan Summary

Live Link to Document on Google Docs

Risk and Problem Tracking

Our risk table has remained largely the same since the conclusion of MSD I with only one low priority risk being added (R15). As we are approaching the build and test phases, some risks are beginning to manifest themselves as problems. We have identified these problems as they arise and are working through plans to mitigate them.
Updated Risk Assessment (2/8/16)

Updated Risk Assessment (2/8/16)

Problem Tracking(2/8/16)

Problem Tracking(2/8/16)

Obtaining Ultem

The biggest issue of this phase has been obtaining Ultem with which to print. Our original plan was to order Ultem from Fisher-Unitech but we discovered we are out of their ordering range. Alternatively, we tried to order Ultem from Stratasys but they were reluctant to sell filament directly to us. Due to the importance of obtaining printing material, we have developed several alternatives and backups.

Delrin Printing

During our material selection phase, Delrin was our second choice to print in. Due to the issues that have arisen with Ultem printing, the use of Delrin as a material was reconsidered. Delrin is relatively cheap and easy to purchase, costing only $50 for a 1kg spool of filament. Delrin also has the advantage of having similar physical properties to Ultem so that some testing, and even the final product, could be made of Delrin if absolutely necessary. Despite the similarity in mechanical properties between Delrin and Ultem, if the final product were to be built in Ultem, Delrin tests would not give us as much confidence in the viability of an Ultem CubeSat as if we used the real thing during tests. Dr. Cormier has also expressed reluctance to print in Delrin due to the potential toxicity of the material at high temperatures. Because of these drawbacks, we consider printing in Delrin to be an inferior option. Delrin printing will not be considered again unless we are unable to purchase Ultem from a third party out of state.

Alternate On Campus Print

A Fortus 360MC is apparently in the Golisano College of Computing and Information Sciences. A previous group has printed with Ultem on campus on this printer this is the link to their home page. The group created a device that required the use of Ultem 9085 to 3D print their parts. Documentation would suggest that their is a printer on campus.

Stratasys Sponsorship

In our search for more Ultem sources, an Ultem distributor recommended us to the Stratasys sponsorship program. He felt that our unique project may be something that Stratasys would be interested in supporting. We have applied to the program and are waiting for a response in the coming days. This would give us the ability to print our Ultem parts for free. In exchange for this service, they would like us to share a report of our project and how Stratasys was able to help us create our parts.

Outsourcing Quotes

Incept3d-$650, 2 Weeks Lead Time

Stratasys-$450, 3 Day to Ship

Resource Plan

Resource Plan(2/10/16)

Resource Plan(2/10/16)

Ordering Status

Many of our parts have been ordered and have come in. There have been issues with a few of the parts that have prevented procurement to this point. The current ordering status is reflected in the bill of materials below. The BOM has also been updated to reflect the choice to purchase a pre-made hinge shaft for the deployable arrays rather than machine one ourselves as well as some minor supplier changes.
Updated BOM(2/8/16)

Updated BOM(2/8/16)

Design Updates

Updated BOM(2/10/16)

Updated BOM(2/10/16)

Some changes were made in the design of the rails to account for hardware. Holes were added in the ends to allow assembly of the plunger spring and deployment switch.

February 11th Design Revision

Simulation Verification


To validate our vibration simulation techniques used in MSD Phase I, we spoke with a subject matter expert from the mechanical engineering department. After reviewing our procedure with Dr. Ghoneim, he agreed that we had accurately represented the launch conditions, assuming our design does not contain any loose parts.

Acoustic vibrations are not a concern for our design due to the fact that the acoustic pressure is minimal, and the materials we used have strong damping characteristics.

How will thermal expansion affect the clearances in our hinge mechanism?

Based on calculations from our nominal hinge size, and Ultem's low thermal expansion coefficient of 65e-6 m/(m C). Even across the entire operating range of the CubeSat from -40 to 40 C, the critical hinge dimensions will change by less than 0.0005" this small change in dimensions will not adversely affect hinge performance.

Ultem High Temperature Performance

Plans for next phase

MSD Plan(Updated 2/3/16)

MSD Plan(Updated 2/3/16)

Individual Goals

Anthony, System Integrator

Paul, Deployable Mechanism Designer

Rob, Structures Designer

Tristan, Deployable Device Designer


Conference Due Date
NCEES Engineering Award May 2nd 2016
IIE Student Technical Paper ????
ASME IAM3D Challenge April 15th 2016
International Astronautical Congress Feb 29th 2016

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