Development of a 100 gm class inspector satellite using photostructurable glass/ceramic materials

A pulsed UV laser volumetric direct-write patterning technique has been used to fabricate the structural members and key fluidic distribution systems of a miniature 100 gm mass spacecraft called the Co-Orbital Satellite Assistant (COSA). A photostructurable glass ceramic material enables this photo-fabrication process. The COSA is a miniature space vehicle designed to assist its host ship by serving as a maneuverable external viewing platform. Using orbital dynamics simulation software, a minimum DeltaV solution has been found that allows a COSA vehicle to eject from the host and maneuver into an observation orbit about the host vehicle. The results of the simulation show that a cold gas propulsion system can adequately support the mission given a total fuel volume of 5 cm(3). A prototype COSA with dimensions of 50 x 50 x 50 mm has been fabricated and assembled for simulation experiments on an air table The vehicle is fashioned out of 7 laser patterned wafers, electronics boards and a battery. The patterned wafers include an integrated 2-axis propulsion system, a fuel tank and a propellant distribution system. The electronics portion of the COSA vehicle includes a wireless communication system, 2 microcontrollers for systems control and MEMS gyros for relative attitude determination. The COSA vehicle is designed to be mass producible and scalable.