Deployable Solar Array Test

About This Project

Design and fly a custom deployable solar panel mechanism on a 2U CubeSat. Validate deployment reliability, power generation improvement over body-mounted cells, and mechanical performance in microgravity.

Overview

Solar panels are the primary power source for nearly every satellite, and maximizing power generation is a constant design challenge. Body-mounted panels are simple and reliable but limited in area by the satellite's external surface. Deployable arrays unfold after launch to expose significantly more cell area, dramatically increasing available power — but at the cost of mechanical complexity and deployment risk. This project designs, builds, tests, and flies a custom deployable solar panel mechanism, then validates its performance in orbit against predictions. Students work through the full mechanical design lifecycle: conceptual layout, detailed CAD modeling, finite element analysis of hinge loads and thermal cycling, prototype fabrication, deployment testing in thermal-vacuum conditions, and finally integration and flight. The experiment instruments both the deployable and body-mounted reference panels to compare power generation, track degradation over time, and correlate performance with orbital parameters like sun angle and eclipse duration. This is primarily a mechanical engineering challenge and one of the best projects for students who want hands-on experience with space-grade mechanism design.

Technical Details

Design hinged deployable panels with tape-spring or burn-wire release mechanism. Use triple-junction GaAs cells (>29% efficiency) or lower-cost silicon cells for the demonstration. Instrument with current/voltage sensors (INA219, I2C, ~$5) on each panel plus reference body-mounted cell. Log power generation vs panel angle, eclipse transitions, and thermal cycling. Deployment mechanism: nichrome burn-wire + nylon restraint, redundant with timer-based backup. Validate with thermal-vacuum testing before integration.

Research & Notes

Sparrow platform supports fixed or double deployable arrays (1U-6U) with triple-junction GaAs cells >29% efficiency, output 15-90W depending on area/orientation. Deployable hinge/tape-spring/burn-wire options already in platform roadmap. Deployment mechanisms are historically one of the highest-risk CubeSat subsystems — Warsaw PW-Sat2 (2018) successfully deployed a sail mechanism; many others have failed. Requires FEA analysis of hinge loads, thermal cycling simulation, and extensive ground testing. Primarily a mechanical engineering project — ideal for ME students with FEA, mechanism design, and prototyping skills. Cost: $1,500-$5,000 for cells + mechanism + instrumentation. Complexity: advanced. 3U form factor needed for adequate rail length for hinged panels and actuators.

Required Disciplines

This project spans 4 disciplines, making it suitable for interdisciplinary student teams.

Next Steps

Ready to take on this project? Here's a general roadmap that applies to most CubeSat missions:

1. Build your foundation: Complete the core modules in the CubeSat Academy to understand spacecraft subsystems, mission design, and development workflows.
2. Form a team: Recruit students across the required disciplines and identify a faculty advisor. Plan for knowledge transfer between graduating and incoming members.
3. Write a mission concept: Draft a 1–2 page document outlining your objectives, target orbit, payload requirements, and success criteria.
4. Connect with a chapter: Join a Blackwing chapter for mentorship, shared resources, and access to the platform ecosystem.
5. Explore the developer tools: Visit the Developer Portal for platform documentation, SDKs, and hardware specs.
6. Plan your timeline: Map milestones to your academic calendar. Most projects align well with a 2–4 semester capstone or research sequence.
7. Reach out: Contact us to discuss your project goals, platform selection, and path to orbit.