JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 75

edges, and six in the corners. Traditional “add plies” are eliminated by
providing generous ply overlaps along
the edges. This reduces mass and cost
because doubled and tripled face-sheet
zones can be added without extra engineering effort or significant new touch
labour. In addition, modularity minimizes the post-cure bonding and paneljoining operations typical of traditional
composite spacecraft manufacturing.
To accommodate the variability
required for diverse missions and everchanging instrumentation, modules
can be customized while a vehicle is
being fabricated. These modifications
can include things like trimming away
decks and/or walls to make room for
internal equipment, or adding inserts
for additional equipment attachment
points. In other words, while the modules themselves can be a cookie-cutter
design, in the end, each spacecraft will
be unique.

The modular makeup of LADEE
After lengthy design exploration,
the Ames Common Bus took its first
flight-programme shape in 2008 as the
Lunar Atmosphere Dust Environment

Explorer, or LADEE. The spacecraft –
which is scheduled to launch in 2013
and fly in low orbit around the moon
– will analyze lunar atmospheric dust, a
phenomenon first observed by Apollo
astronauts on moon missions between
1969 and 1972.
To house the necessary mission-specific
instrumentation, the LADEE vehicle
is four modules high, which is tall by
small-satellite standards (see Figure 1).
The two bottom modules contain the
propulsion system. Located on the top
two tiers are instruments for avionics,
communications, and the science experiments. These include: an ultraviolet
spectrometer that uses solar occultation
to examine the moon’s dust; a “lunar
dust experiment” that samples and
vaporizes the particulate; and a neutral
mass spectrometer capable of measuring the mass and elemental makeup
of the vaporized particles. Solar panels
are mounted around the sides of the
modules.
When assembled, LADEE’s four-module skeleton (without instrumentation) weighs only 46 kg. Of that total,
70% is composite-faced panels, 5%
aluminium-faced panels, and 25% a
combination of metallic inserts, fittings,
and brackets. Once the scientific payload has been added in, the craft still
weighs only 130 kg – about average for
an NFL lineman but pretty light for a
satellite. At launch, it will be about 363
kg wet mass.

The importance of cutting
weight and the role of software

Fig. 1: Computer-generated models of the NASA
Ames Lunar Atmosphere Dust and Environment
Explorer (LADEE) spacecraft show the module
stack assembled (top) and in “exploded view”
(bottom). The two top tiers will house the science
experiments, avionics, and communications
equipment. The two bottom modules contain the
propulsion system. Solar panels are not shown in
this view. (Credit: NASA/Ames)

Minimizing structural weight for a
spacecraft has obvious benefits. It saves
fuel, allows for larger scientific payloads, and reduces manufacturing costs.
As the materials and analysis lead on
the LADEE project, Ian Fernandez was
responsible for watching vehicle weight
along with the portfolio of software
tools needed to find solutions and the
engineers using them. People on the
team wear multiple hats. The team has
had three designers, about three full-

time analysts, and student interns doing
a variety of things. When you total up
the core and auxiliary team members
for LADEE, there are almost thirty.
The engineer’s tools included ProEngineerCAD with Windchill and MINX
providing configuration control.
ProMechanica handled analysis of
small parts such as brackets. PATRAN
served as the pre-processor and the
home of the master finite element
model (FEM). And NASTRAN was
the workhorse finite element analysis
(FEA) solver.
This software toolbox was completed
with HyperSizer, a structural sizing
and optimization package for composites and metals from Collier Research
Corporation. HyperSizer is a robust
analysis tool. It has excellent concept
trade study abilities, extensive failure
mode equations, and streamlined data
management, and it calculates margins
for the final detailed design. It also
interfaces and iterates seamlessly with
NASTRAN.
Fernandez had learned the code (first
developed at NASA) while taking a
two-year detour from the Common
Bus project to work on the Agency’s
forward-looking Composite Crew
Module (CCM). While there, he
experienced hands-on how HyperSizer
helped optimize and lighten the CCM
throughout the development cycle,
reducing weight by about 20% and enabling the CCM to pass the strictest physical testing with flying colours. Back
at LADEE, he suggested the tool as a
complement to the collected capabilities of the other analysis software, and
the team responded positively.

Optimization proves-out
lightweight composite designs
With flight programme status and
funding for LADEE in place, that’s
when the gears really started to turn
hard. Early in design, the engineering
group employed HyperSizer to perform
rapid and extensive trade studies on the

No83 August - September 2013

/ jec composites magazine 75



JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013

Cover
Edito
Point of view > looking to the future
Contents
Agenda of Events
COMPANY & BUSINESS In Brief
APPLICATIONS
Elevator
Sport & leisure
Defense
E.V.
MARKET
Automotive
US market
SPECIAL JEC AMERICAS
9th I.C.S.
Awards
Canada: country guest of honor
RESEARCH & DEVELOPMENT
Graphene
Tow placement
TECHNOLOGY & INNOVATIONS
NDT
Software
Epoxy
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Cover
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 2
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Edito
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Point of view > looking to the future
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 5
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Contents
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 7
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 8
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 9
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 11
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Ad1
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Ad2
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - COMPANY & BUSINESS In Brief
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 13
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Elevator
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 15
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Sport & leisure
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 17
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Defense
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 19
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - E.V.
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 21
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Automotive
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 23
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 24
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 25
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - US market
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 27
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 28
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 29
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 9th I.C.S.
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 31
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 32
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 33
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Awards
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 35
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 36
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 37
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 38
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 39
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Canada: country guest of honor
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 41
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 42
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 43
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 44
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 45
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 46
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 47
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 48
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 49
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 50
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 51
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 52
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 53
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 54
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 55
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 56
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 57
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 58
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 59
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 60
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 61
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Graphene
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 63
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Tow placement
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Index
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 66
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 67
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - NDT
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 69
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 70
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 71
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 72
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 73
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Software
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 75
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 76
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 77
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - Epoxy
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 79
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 80
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 81
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - In the world
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 83
JEC COMPOSITES MAGAZINE - Issue #83 - August/September 2013 - 84
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