Harika Mark-1 CubeSat Structural Design

Overview

Harika Mark-1 is a 3U CubeSat built around a CNC-machined monolithic Al-7075 chassis that eliminates structural fasteners while meeting Cal Poly CDS and PSLV constraints. The design integrates internal rails for a longitudinal motherboard and modular PCBs, simplifying assembly and servicing. Static and modal FEA in ANSYS verified that the frame comfortably survives worst-case launch loads with minimal stress and deformation, providing a stiff, low-mass platform for student and research missions.

Outcomes

• CNC-machined monolithic 3U chassis that improved structural rigidity by roughly 25% while reducing frame mass by about 15% compared to conventional fastened CubeSat structures.
• Static analysis in ANSYS showed a maximum von Mises stress of 4.7 MPa and peak deflection of 0.0078 mm under 12g PSLV-equivalent launch loads, well below the yield limits of Al 7075-T6.
• Modal analysis produced first natural frequencies above 270 Hz, exceeding PSLV requirements and confirming sufficient stiffness for safe deployment from standard CubeSat dispensers.