warning

🚧 This document is still being actively worked on and is subject to change. 🚧

Responsible	Janik Hackel
Last Updated	10/12/2025, 12:48:54 PM
Last Author	Kai Berszin

General Report

The purpose of this document is:

• Define which tests should be done and to what extent
• Link all reports that should be done
• Give an overview of the results of the tests

EQM

As it is very expensive to test the CubeSat with flight-hardware, we decided to only use flight-hardware where it is necessary and has minimal consequences if the part is destroyed.

Part (Name according to TC-File if possible)	Do we use an EQM-Dummy
z minus Plate Endurosat	No
z plus Plate Endurosat	No
Frame	No
Support bar	Yes
Sensoren	Yes
Testing equipment (Adapter for Shakertable and TVAC)	Yes
Side-Panel	Yes
Top Panel	Yes
Spacer Camera	Yes
Spacer brass	Yes
Spacers PEEK	Yes
Washers PEEK	Yes
Payload	Yes
PC104	No
Cables	Yes
EPS-Battery Board	Yes
EPS-Control Board	Yes
OBC Board top	No
OBC Board bottom	No
GNSS-Antenna	No
S-Band Antenna	No
Arducam	Yes
UHF Release	No
Radiation projection for OBC	No
SatNOGS	Yes
UHF-Antenna	No
ADCS Core	Yes
ADCS Sun Sensor	Yes
ADCS Earth Sensor	Yes
ADCS CubeMag Deploy	Yes
Solar panel	Yes (from TC)
Reflector	Not used

Please note that there are parts in the list that are not part of the CubeSat itself (e.g. the adapter and the test stand for the cables experiment).
Also note that all self-designed parts will be tested in their flight configuration (except for smaller connectors used for debugging).

Testing Adapter

The testing adapter is used to mount the CubeSat to the vibration table. The goal is to have one adapter for all tests. It should be designed according to the criteria defined in the work package presentation.

Cable Testing Equipment

The plan for this testing platform is to have a mount that includes all cables and connectors used in the mission and verify if they can withstand the mechanical forces.
Additionally, we will examine the behavior of the cables.

Test Selection

The general testing requirements can be found in:

• Test input tolerance: ECSS-E-ST-10-03C 4.4.2
• General requirements: ECSS-E-ST-10-03C 5.1
• Thermal vacuum outgassing: ECSS-Q-ST-70-02C
• Fracture control: ECSS-E-ST-32-01C (Procedure in 5.2 and 5.3.2.4)
• Thermal Balance Test: ECSS-E-ST-31C (4.5.3)
• The PUG of SpaceX

The launch provider is currently unknown, but these are the strictest requirements we found.
As the CubeSat weight class (below 10 kg) is not always explicitly listed, we decided to use the lowest one and extrapolate requirements.

Information sources:

• Instar Engineering CubeSat Testing Manual (see 09 Testing, Literature)

Qualification Test

• Demonstrate the adequacy of design by testing a dedicated non-flight article under conditions more severe than expected for the mission.
• This is our main testing campaign.
• We increase the margin by 0.1 to account for uncertainties and variations in the parts.

Dimensional Verification

• Check the full assembly for space constraints and feasibility of assembly. This is done for both the flight model and EQM.
• Virtual Testing: Done in TC or NX before confirming orders.
• Physical Testing: Assemble the satellite in a test run.

Quasi-Static Load

• Requirement level: Required
• Qualification: Minimum 1.25x limit load on each axis (Table 6-4, 6-5)
• Testing: Adapted to 1.35x limit load on each axis
• Purpose: Verify structure can withstand static loads
• Test: Performed once with the total setup

Sine Burst

• Requirement level: Not specified
• Qualification: Not specified
• Purpose: Strength test for primary structure
• Shaker imparts sinusoidal acceleration at low frequency to avoid dynamic amplification.
• Result: Near-uniform acceleration
• Use Case: Preferred if dynamic tests don't sufficiently stress the structure
• Test: Performed with full setup
• Reasoning: Verify structure withstands mass of slightly heavier CubeSat

Sine Vibration

• Requirement level: Advised
• Qualification: Min 1.25x limit load, 2 oct per min sweep rate in each of 3 axes
• Testing: Adapted to 1.35x limit load with 2 oct per min sweep rate in all axes
• Tests mechanical integrity with sinusoidal acceleration
• Not needed if covered by sine burst and random vibration
• Test: Not performed
• Reasoning: Already covered by other tests

Acoustics

• Requirement level: Advised
• Qualification: Max predicted environment + 6 dB for 2 min
• Testing: Not performed
• Reasoning: Forces are minimal and overlaid by more critical low-frequency forces

Shock

• Requirement level: Advised
• Qualification: MPE (15g) + 6 dB for 6 min
• Testing: Adapted to MPE (18g) + 6 dB for 6 min
• Test: Performed once with full build
• Reasoning: Shock can only be induced by the P-Pod

Random Vibration

• Requirement level: Required
• Qualification: MPE + 6 dB for 2 min on each of the 3 orthogonal axes
• Testing: Same as qualification
• Tests mechanical integrity under cyclic loading and multiple frequencies (20–2000 Hz)
• Possible failures: Loose connectors, fastener loosening, small part rupture
• Test: Performed on EQM, cable setup, Biopayload (TBD)

Low-Level Sine Sweep

• Low-level version of sine vibration test
• Determines natural frequencies and damping
• Assesses structural integrity after high-level tests
• Frequency range: 20–2000 Hz
• Sweep rate: Logarithmic, slower for low-damping structures
• Test: Performed before and after every major test
• Reasoning: Detect structural shifts or damage

Thermal Vacuum

• Requirement level: Advised
• Qualification: Acceptance + or - 10 degree C for 27 cycles
• Testing: Same as qualification
• Test: Performed once with total setup
• Reasoning: Ensure satellite survives environmental stress
• Conducted in combination with thermal cycling.

Thermal Cycle

• Requirement level: Advised
• Qualification: MEOP per section 6.10 (SpaceX PUG)
• Testing: Same as qualification
• Test: Performed on the entire satellite
• Reasoning: Test thermally induced stress only makes sense when done on the full system
• Conducted in combination with thermal cycling.