Design, fabrication and test of functional panels for multi-mission modular satellite platform

In this case study, an integrated approach for the design and fabrication of a titanium (Ti) panel test made by additive manufacturing is proposed. The panel has been conceived integrating its mechanical properties for the structural support and for loading all the components and payloads of the satellite platform, with the innovative property of heat dissipation. The metallic structures has been designed for the allocation of the battery pack of the payload and for positioning electronic cable and optical fibers. This prototype module comprises internal heat pipes, containing numerous parallel micro-channel arrays, for managing the heat exchange related to the working condition of the payloads. The profile and section of the micro-channels have been designed to favor the liquid evaporation under heating in microgravity condition and thus for different space applications. 3D printing has been selected for the realization of the Ti panel and the construction of the internal channels (heat pipes), holes for cable connection, niche for housing the external battery and all the components required for filling it by an appropriate refrigerant fluid. The thickness distribution of the panel is not uniform, in fact for reducing its total mass some parts have been realized reducing the amount of material dispensed. In the following the design and fabrication of the prototype is illustrated and discussed. In the design particular attention was focused to the balance of the profile selected for the heat-pipes and the 3D printing resolution. The characterization of the working condition under heating has been also reported and discussed. We believe that functional panels with these novel characteristics would find application for energy waste recovery also in case of electronic dissipation for module dedicated to space exploration