Advanced Dual-Hinge SMA-Based Solar Panel Deployment Mechanism for a 3U CubeSat: Structural Optimization and Multi-Thickness PCB Integration Under JAXA Constraints
- Paper ID
101579
- DOI
- author
- company
Laboratory of Spacecraft Environment Interaction Engineering, Kyushu Institute of Technology; Kyushu Institute of Technology
- country
Japan
- year
2025
- abstract
The development of compact and efficient solar panel deployment mechanisms is critical for CubeSat missions, particularly under strict mass, volume, and structural constraints. This study presents the design, optimization, and experimental validation of a dual-hinge Shape Memory Alloy (SMA)-actuated deployment system for a 3U CubeSat, engineered to comply with the Japan Experimental Module Small Satellite Orbital Deployer (J-SSOD) envelope requirement, which imposes a 6.5mm thickness constraint on deployable components. The proposed mechanism integrates two hinge configurations: (1) a primary hinge connecting the CubeSat structure to the solar panel, and (2) an inter-panel hinge enabling a sequential folding deployment. To evaluate mechanical performance and deployment efficiency, three PCB FR-4 thicknesses (0.3mm, 0.5mm, and 1.0mm) are investigated, analyzing their structural rigidity, bending characteristics, and deployment reliability in spaceflight conditions. The proposed SMA-based Solar Array Panel (SAP) deployment mechanism builds upon the design successfully demonstrated on the LEOPARD satellite, where the SMA-driven system met safety and envelope requirements within a 6.5mm height constraint. Leveraging the insights gained from LEOPARD, the refined mechanism in this study integrates improved SMA actuation performance, enhanced deployment stability, and optimized hinge configurations to ensure higher reliability and adaptability for future CubeSat missions. The SMA actuator is selected for its compactness, high energy density, and repeatable shape recovery properties, ensuring reliable deployment with minimal power consumption. Finite Element Analysis (FEA) and topology optimization are applied to minimize mass while maintaining structural integrity. Additionally, metal 3D printing is utilized to fabricate lightweight, high-strength hinge components, enhancing deployment accuracy and durability. To verify the system’s functionality and resilience, a series of deployment functional tests is conducted, evaluating deployment speed, hinge actuation performance, and structural stability. Furthermore, the mechanism undergoes thermal exposure tests to assess its performance under extreme temperature variations in Low Earth Orbit (LEO). Finally, vibration testing is performed to simulate launch conditions and mechanical loads, ensuring reliability under real-world spaceflight stresses. The results demonstrate a scalable, high-reliability SMA-driven deployment mechanism, providing an efficient solution for CubeSat solar array expansion. The findings contribute to next-generation small satellite power systems, enabling compact, energy-efficient, and structurally resilient deployable mechanisms for future space missions. {\bf Keywords:} 3U CubeSat, Shape Memory Alloy (SMA), Solar Panel Deployment, Dual-Hinge Mechanism, Metal 3D Printing.