Date of Award


Document Type


Degree Name

Master of Science (MS)


Aerospace, Physics, and Space Sciences

First Advisor

Frank Bourne

Second Advisor

Daniel Kirk

Third Advisor

Markus Wilde

Fourth Advisor

Hamid Hefazi


The AddCube mission aims to demonstrate additive manufacturing technology in microgravity on a CubeSat platform by 3D-printing a 1-meter long rectangular beam on orbit. To accomplish this task, Made In Space Inc. (MIS) will provide the Extended Structure Additive Manufacturing Machine – CubeSat (ESAMM-C) payload. The high power required by the ESAMM-C payload creates a complex thermal problem within the spacecraft due to tight volume constraints associated with CubeSats. To cope with this problem, an in depth worst-case thermal analysis of the integrated spacecraft is conducted and an appropriate thermal management system for the mission is designed. Temperature regulation is achieved through the use of passive thermal control methods during the hot case and flexible strip heaters during the cold case. A quasi-static loads analysis proves the payload’s structural mounting interface should be re-examined and an alternative design approach should be taken to ensure the spacecraft will survive the launch and deployment environments. The following thesis outlines the preliminary design and analysis of a 6U CubeSat, including all subsystems required to complete a successful mission.