In 2015, MITRE introduced a new class of wideband phased array antenna technology called the Frequency-Scaled, Ultra-Wideband, Spectrum Element (FUSE™) array. Since then, MITRE has continued to advance the technology improving electrical performance and manufacturing design to expedite deployment into the field. One such improvement was to redesign the FUSE™ antenna to be additively manufacturable in 2017. Additive manufacturing (AM) reduced manufacturing complexity to one or two steps (depending on the array design), fabrication and labor-intensive assembly costs by up to 50%, and fabrication time from months to weeks. Furthermore, the unique capabilities of AM enable the use of internal latticed structures which can result in 50% weight reduction. This paper discusses a follow-on study to the first AM FUSE™ array comparing the design and manufacture of two new FUSE™ antennas operating between 1 and 6 Gigahertz (GHz) with identical geometries but built via different additive manufacturing processes: direct metal laser sintering (DMLS) and stereolithography (SLA). The SLA part was metal plated to achieve RF and structure requirements and is referred to as the “plated-stereolithography (p-SLA) FUSE™”. Both versions exhibit nearly identical RF performance while benefitting from unique attributes of each manufacturing design.

The current development process for spacecraft consists of designing for mission goals first and mitigation for environmental requirements second. Environmental issues often arise late in the design process, leading to longer design times and less efficient use of the available volume and mass. Faster and more efficient development of spacecraft can be achieved through a novel design methodology, Multi-Physics Topology Optimization (MPTO). The work presented provides an overview of a MPTO for small satellite design, combining thermal management and structural design into a single, streamlined process. This method results in a more effective use of allotted mass and volume, providing opportunities to increase system functionality. An example case is provided using an existing 3U CubeSat, where the proposed methodology was used to improve specific performance attributes. As topology optimization technologies continue to develop, this method can be expanded to include new capabilities, such as multi-material optimization, as well as new objectives, such as optical and electrical performance.