Development of efficient and cost-effective spacecraft structures based on honeycomb panel assemblies

Due to their high strength to weight ratio and stiffness to weight ratio the use of honeycomb panels is particularly attractive in spacecraft structures. Honeycomb panels are often used in secondary satellite structures such as equipment platforms and solar arrays, but they can also be used as part of the primary structure of a satellite. Indeed honeycomb panel assemblies can be, and are, used to produce efficient and cost-effective primary structures. These types of structures have been used for some time for numerous satellites; however, their development still poses some challenges ranging from the structural performance of the panels themselves to the problem of connecting them to other panels or structural elements. These challenges are faced each time a new satellite is being developed adding cost to the design process. Furthermore, often due to strict timescales in the development process, some of the uncertainties which naturally arise from these challenges cannot always be completely addressed. To compensate for this, conservative design approaches often need to be taken with the ultimate effect of lowering the efficiency of the structure's final design. To meet these challenges and provide a better knowledge base for future satellite development projects a number of research activities have been, and are still, under way at the University of Southampton. The aim of this paper is to describe these research activities and present the key results.