Prototyping of casted lightweight antenna for satellite communication (PROTOSAT)

Purpose and goal:

The purpose of the project was to evaluate whether Satcube´s antenna could be mass-produced cost-effectively using casting. An important sub-goal of this was to reduce the weight of the antenna, since increased weight means that the antenna has to be mounted on more expensive motors and mechanics.

The project demonstrated that casting is possible, albeit very complicated. Casting in aluminum was verified in practice, and in magnesium in theory. Unfortunately, no foundry was willing to do a magnesium prototype. Both Satcube and RISE are satisfied with the outcome of the project. Expected results and effects:

Satcube did not expect the limited time frame of the project to fully verify casting technology as a viable option, which it did not. However, the project demonstrated that it is possible, but that Design for Manufacturing is a philosophy that must be taken into account.

The project demonstrated that thin and lightweight structures could be realized, and indicated that further weight reduction can be achieved by switching to magnesium. Overall, the project has thus given a clear indication that weight and cost reduction by means of casting is possible. Approach and implementation:

Satcube and RISE conducted a theoretical cross-disciplinary analysis to identify the necessary modifications to Satcube´s antenna geometry that were necessary for casting to be possible. The outcome of this study was an antenna design that could be cast in a sand mold. The performance was a little lacking, but still good enough to indicate that the more accurate casting technique using a ceramic mold is very likely to work.

Several sand-cast prototypes were produced and analyzed. A ceramic cast prototype is being made, but has not yet been finished.