Composites in Space

A general overview of composites opportunities within the

UK Space Sector

By Michael Comport
Contents

1. UK’s Space Strategy

 Civil Space Industry
 MOD
2. The Space Environment
3. Why Use Composites?
4. How are/could be Composites Used in the Space Industry
 Launch Vehicles
 Satellites
 Human Space Flight
5. UK Space Industry

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UK Space Strategy – Civil Space Strategy - 1
• Prosperity from Space – Space Growth Partnership 2018
• 10% market share by 2030, up from 5.1% in 2016
• Four space sector priorities
• Earth information services, e.g. navigation, security etc.
• Connectivity services, e.g. communications, IoT
• In-space robotics
• Low-cost access to space
• Four pillars that make up the future strategy
• Creating a national space programme
• Creating the right environment for success
• Investing in people and places
• Continuing to drive growth from investment in international collaborations
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UK Space Strategy – Civil Space Strategy – 2
• Harwell Space Cluster – Didcot
• Central hub where large amount of industry is based
• RAL Space
• Satellite Applications Catapult
• UK Space Agency etc.
• Grow to 200 companies and 5000 employees by 2030
• Launch UK
• Establish vertical & horizontal small satellite launches from UK soil
• Spaceflight capable from the early 2020s
• Vertical launch site in North Scotland
• First launch in 2022
• Horizontal spaceport in Newquay, Cornwall (Virgin Orbit)
• Become the world leader in small satellite launches in the 2040s |
UK Space Strategy – Civil Space Strategy – 3
• Artemis
• An international collaboration to return to the moon
• UK businesses will be involved in the “Lunar Gateway”
• £16m invested so far
• “Lunar Pathfinder”
• Relay satellite to be developed by SSTL
• Satellite Application Catapult
• Help organisations make use of satellite technologies
• Drive economic growth through space exploitation
• Help grow space industry to £40bn by 2030
• Directly stimulating £5bn
• Deliver 5 in-service demonstrators
• Increase UK exports |
UK Space Strategy – Ministry of Defence – 1
• MoD Space Strategy
• Vision:
• “To secure freedom of action in space, fully exploiting its military and civilian
potential”
• Mission:
• “To ensure the Defence has the capabilities, skills and operational plans to protect
and defend its space assets and interests in an increasingly contested environment,
working closely alongside the rest of Government, international partners and the
private sector.”
• Strategic Objectives:
• Enhance space resilience and operational effectiveness
• Optimise space support to the front line
• Support wider Government activities
• Holding the “Defence Space 2020” conference this week (17th & 18th) |
UK Space Strategy – Ministry of Defence – 2
• Carbonite 2
• 1st demonstrator in a project to stream live 3D video to pilots
• SSTL developed and built the satellite
• Skynet
• Constellation of multiple satellites for military communications
• Skynet-5
• Launched 2007-2012
• Skynet-6A
• £500m contract with Airbus Defence and Space
• Schedule for launch in 2025

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UK Space Strategy – Ministry of Defence – 3
• Dstl’s Space Programme – 2017-2022
• Collaboration with SSTL in running a satellite ground station
• Maintain Defence’s core expertise and capabilities
• Develop future technologies
• Key activities:
• Reducing size, weight and power requirements of satellite payloads
• Working with experimental satellites
• Exploring protection against space hazards
• Testing emerging concepts and technologies
• Olympic Defender
• Coalition between the USA and UK
• Strengthen the defence of space assets
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 The Space Environment
Thermal Cycling
• Dependant on orbit parameters
• -150°C to 110 °C [1]
Ultra-High Vacuum
• Outgassing [2]
• Instrument contamination
• Reduction in mechanical performance
Cosmic Radiation
• Crosslinking
Elemental Oxygen
• Resin erosion [3]
Space Debris and Meteoroids [4]
[1] – Vayer, B, “Solar Array at Very High Temperatures: Ground Tests”, Spacecraft Charging Technology Conference, 15/08/2016
[2] - Pasotre R, Delfini A, Albano M, Vricella A, Marchetti M, Santoni F, Piergentili, “Outgassing effect in polymeric composites exposed to space environment thermal-vacuum conditions”, Acta Astronautica, 03/01/2020
[3] – He Y, Suliga A, Brinkmeyer A, Schenk M, Hamerton I, “Atomic oxygen degredation mechanisms of epoxy composites for space applications”, Polymer Degredation and Stability, 20/05/2019
[4] – Moorhead A, Matney M, “The ratio of haxardous meteorides to orbital debris in near-Earth space”, Advances in Space Research, 08/09/2020 |
Why Use Composites?

• Lightweight
• Launching payloads into space is expensive ~ £10k per kg
• Maximise “useful” payload
• Tailorable properties
• Design can be maximised for each application
• Low coefficient of thermal expansion (CTE)
• High dimensional tolerance in orbit
• Ablative properties
• Heat protection

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 Composites in Launch Vehicles Nose Tip
• CMCs – high temperature resistance and stability
Nose Tip
Payload Fairings
Payload Fairings
• CFRP/CFRP Al sandwich panels
• Falcon 9 are CFRP and intended to be reusable
Interstage
• CFRP/CFRP Al sandwich panels
Interstage
Cryogenic Tanks Straps Cryogenic Tank Straps
Fuel Tanks • Filament wound – High strength, thermal insulation
Fuel Tanks
Rocket Body • Boeing demonstrator
Rocket Body
• Future vehicles
Rocket Nozzles
Rocket Nozzles
https://www.aerospacetestinginternational.com/news/engine-testing/skyrora-successfully-flight-tests-3d-printed-rocket.html
• UHTCMC/CMC – high temperature resistance and
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stability
 Composites in Satellites

Solar Panel Backing

• Sandwich panels
Solar Panels • High specific stiffness and strength
Struts and Booms
• High specific stiffness and strength
Struts and booms
Primary Structure
Primary Structure
Instrumentation & Antennae • High specific stiffness and strength
Radiation Shields • Low moisture uptake
Instrumentation & Antennae
• Low CTE
Radiation Shields
https://www.ucl.ac.uk/impact/case-studies/2014/dec/pinpointing-satellites-orbit |
 Composites in Human Spacecraft

Primary Structure
• Future spacecraft
Instrument Consoles & Secondary Structures
Primary Structure
• Lightweight
Instrument Consoles Radiation Shields
Radiation Shields Thermal Protection Shields
Thermal Protection Systems
• Ablative materials
Solar Panels
• UHTCMCs
Solar Panel Backing
• Sandwich panels

https://en.wikipedia.org/wiki/SpaceX_Dragon |
The UK Space Industry
Astroscale
Area of Expertise
Headquarters Tokyo, Japan
• Astroscale focus solely on on-orbit servicing working on repair,
servicing and end of life, of in-orbit platform. UK Office(s) Harwell Space Centre
• Astroscale are also working on clearing the growing space debris
problem.
• They are scheduled to launch an End-of-Life Services by
Astroscale-demonstration (ELSA-d) in 2020
• Recently purchased Effective Space – Space Drone™
Where the NCC can Provide Support
• Assistance in design using composites in structures and/or
mechanisms
• Manufacturing appears to be done through contract - SSTL
• Possibility of composite repair in space?

https://spacewatch.global/2018/10/singapores-astroscales-elsa-d-mission-to-be-launched-by-russias-glavkosmos-in-2020/ |
Infinite Orbits
Area of Expertise
Headquarters Singapore
• Infinite Orbits develop and operate life extension plans
• Build a system that tracks and docks onto satellites provide UK Office(s) London
refuelling etc.
• Focusing on: autonomous systems, mechanical docking
• Aim to launch demonstrator in 2020 with operational models in
2021/22

Where the NCC can Provide Support

• Advice on manufacturing of docking systems
• Spacecraft design and manufacturing

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Surrey Satellites Technology Ltd.
Area of Expertise
Headquarters Guilford
• The world’s leading small satellite manufacturer
• 2.4 average launches a year UK Office(s) Bordon, Hampshire
• Currently manufacturing 10 payloads for launch
• Own and operate a dedicated composite and mechanisms
facility

Where the NCC can Provide Support

• Have previously/currently worked with the NCC
• Have previously/currently been a member of NCC
• Might be limited due to SSTL running their own
composites centre

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Airbus Defence and Space
Area of Expertise
Headquarters Stevenage
• Launch vehicles (although now a subsidiary):
• Arianne series rockets UK Office(s) Portsmouth Newport
• Satellites:
• Eurostar series
• Human spaceflight:
• Orion European Service Module

Where the NCC can Provide Support

• Design and manufacture of different aspect of spacecraft
• Utilise the relationship with Airbus Civil Aircraft?

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Open Cosmos
Area of Expertise
Headquarters Harwell Space Centre
• Providing space ready microsatellite platforms to house
payloads UK Office(s)
• They provide 3 variations of microsatellite and assist in
the installation of the payload

Where the NCC can Provide Support

• Design and manufacturing route for the next iteration of
the microsatellite platforms.

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RAL Space
Area of Expertise
Headquarters Harwell Space Centre
• Scientific research centre centred on the space domain
• RAL operate the national satellite test facility UK Office(s)
• Wide variety of space research fields:
• Manufacturing
• Robotics
• Systems engineering

Where the NCC can Provide Support

• Provide manufacturing/design advice for prototype space systems

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Thales Alenia Space UK
Area of Expertise
Headquarters Bristol
• Space system design, integration and manufacturing
• Satellite propulsion UK Office(s) Harwell Space Centre
• Satellite subsystems
• Produced geostationary orbital busses
• Lead design agency in the ExoMars Rover project

Where the NCC can Provide Support

• Further iterations of the orbital busses
• Possibility of developing CMCs in satellite propulsion
systems

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Orbex
Area of Expertise
Headquarters Inverness
• Design and manufacture of a future launch vehicle for
small satellites UK Office(s)
• First launch planned for 2021
• Partnered with the UKSA to provide launches from the
new spaceport in Scotland

Where the NCC can Provide Support

• Scale up of manufacturing for the launch system

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Airbourne
Area of Expertise
Headquarters The Netherlands
• Manufacturing and automated manufacturing of
composite structures UK Office(s) Berkshire
• Solar panel substrate panels
• Panels for mega constellations
• Affordable structures for small launchers

Where the NCC can Provide Support

• Manufacturing
• Possibility of partnering in future projects?
• Combining expertise

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Other Companies
Company Name Area of Interest Location
Exobotics Modular space platforms Cambridge
Reaction Engines Future propulsion engines Oxford
Oxford Space Systems Deployable Antenna Harwell
Skyrora Launch Vehicles Endinburgh
AAC Clyde Nano-satellite technologies Glasgow
Raptor Aerospace Small Launch Vehicles Norfolk
Elecnor Deimos Engineering Consultants Harwell
Nano Avionics Nano Satellite Busses Basingstoke
B2 Space Low Earth Orbit Launchers Newport
Avealto High Altitude Platforms London