Mechanical Optimization of the UPMSat-3 Platform for Satellite Constellation Industrialization

The rapid expansion of the satellite constellation market requires spacecraft platforms designed for highly scalable manufacturing, increased production throughput, and agile integration workflows. This work presents the mechanical optimization of the UPMSat-3 microsatellite bus to facilitate its transition toward serial industrial production. A modular structural redesign is developed based on Design for Manufacturing and Assembly (DFMA) principles, shifting traditional serial stacked integration into a parallel assembly scheme enabled by kinematic self-aligning guides, thereby decoupling assembly tasks, eliminating integration bottlenecks, and streamlining production line efficiency. Concurrently, high-pressure injection molding and fused deposition modeling (FDM) using 30% short-carbon-fiber-reinforced polyetheretherketone (PEEK-CF30) are evaluated as industrial manufacturing alternatives to conventional machined Aluminum 7075-T6. Preliminary structural feasibility is analyzed through Finite Element Method (FEM) simulations under representative launch load conditions. Quantitative results demonstrate an 8.43% reduction in global assembly complexity (CTotal) driven by a 38.36% drop in handling complexity (C1) alongside the potential for structural mass reduction through the use of PEEK-CF30. These findings demonstrate the potential of integrating modular architectures with high-throughput polymer processes as a viable strategy to enhance manufacturing capacity and shorten lead times in the industrialization of future satellite constellations.