PurposeThis paper illustrates an effective application of rapid prototyping (RP) to produce a high definition polymer model of a satellite structure prior to final machining of the aluminum panels. The benefits when using this type of model in the design and assembly stages of satellite fabrication make clear that RP can and should play an important role in the design and fabrication of small satellite structures.Design/methodology/approachSelective laser sintering was utilized to produce a full‐scale model of a novel modular small satellite structure. This model was then used as a tool for quality control, fit check, assembly process verification, mock‐up, and as a model for manufacturing tooling design.FindingsThis case study illustrates that the use of RP to create a model early in the design cycle is beneficial from a cost and time perspective even when applied to a product which will be produced in a quantity of one. In addition, the merits of RP mesh well with modular designs and for applications where assembly and test tooling is required to validate the quality of a product.Practical implicationsThis paper illustrates an effective use of RP in the satellite fabrication industry. The benefits described are generally applicable to other complex systems which need design validation early in the design cycle.Originality/valueThere are few examples of the effective application of RP to produce models, but not the final product, of a complex structure in the satellite and other industries where small lot production occurs.

In the last fifteen years, small satellites have opened a window through which the aerospace industry can rapidly access low earth orbit at a fraction of the cost required by large spacecrafts. Due to its extensive experience with the Space Dynamics Laboratory (SDL), Utah State University (USU) has given students the opportunity to experience the design of such small satellites, nanosatellites or micro-satellites in technical terms. Through the University Nanosat programs organized mainly by the Air Force Research Laboratory (AFRL), USU students have now been involved in two satellite designs since 1999. The author has been and is contributing to both programs. The current program, USUsat 2, has been partially derived from the experience of the previous USUsat I/ION-F program. This paper deals with the USUsat 2 design and more specifically on the manufacturing side and the structure for a modular platform. The author, who has been working as the chief engineer for the program, proposes an approach with a modular design with new structure. The design is intended by the author to have the capability of becoming a micro-satellite platform that future programs could reuse with a minimum amount of upgrade.