Design and verification of a mechanical system for magnetospheric mapping missions

This paper describes the design and qualification of the Space Technology 5 spacecraft mechanical system. Key points include: testing results for the "Frisbee" type deployer system, which imparts a precise spin rate to the spacecraft; layout of the structural bus, with emphasis on design for both compactness and accessibility during assembly; design of the electronics housing, which serves an important dual purpose as the spacecraft structural backbone. Also included is a description of its special accommodations for electrical harness and the integration process; electro-mechanical aspects of the separation connectors and shape-memory-actuated pin pullers; unique challenges due to limited volume and resources were overcome through extensive testing and "skunkworks" type development procedures. Overall, this paper encompasses the unique mechanical system design innovations to enable the 25 kg, fully functional Space Technology 5 spacecraft to blaze a trail towards scale-reduction and system functional integration for upcoming nano-satellite constellations.