The Apocalypse

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Satellite manufacturing ​

Satellite manufacturing is the complex process of designing, fabricating, assembling, testing, and preparing satellites for deployment in space. This section covers the essential knowledge and practical steps needed to restart satellite production in a post-apocalyptic context, focusing on accessible materials, manufacturing techniques, and quality assurance to ensure functional and reliable spacecraft.

Introduction to Satellite Manufacturing ​

Satellites are critical assets for communication, navigation, Earth observation, scientific research, and space exploration. Manufacturing satellites requires multidisciplinary expertise in aerospace engineering, electronics, materials science, and systems integration. In a survival or recovery scenario, rebuilding satellite manufacturing capabilities is a long-term goal that demands careful planning, resource allocation, and incremental development.

This section provides a comprehensive overview of satellite manufacturing, emphasizing practical approaches to produce small to medium-sized satellites using available resources. It covers satellite design principles, structural materials, electronic components, assembly methods, environmental testing, and launch preparation.

A photo of a cleanroom environment where technicians in white suits assemble a small satellite, focusing on precision and cleanliness in the manufacturing process.

Satellite Design Principles ​

Mission Definition and Requirements ​

Every satellite begins with a clear mission objective, which defines its design requirements. Common satellite missions include:

  • Communication (relay, broadcast)
  • Earth observation (imaging, weather monitoring)
  • Scientific research (space environment, astrophysics)
  • Navigation and positioning (GPS-like systems)
  • Technology demonstration

Defining the mission determines the satellite’s size, weight, power needs, payload instruments, and operational lifespan.

Modular and Scalable Design ​

In resource-limited environments, modular satellite designs are advantageous. They allow easier assembly, testing, and repair. Standardized modules for power, communication, propulsion, and payload simplify manufacturing and integration.

Size and Weight Constraints ​

Satellites must be lightweight to reduce launch costs and complexity. Typical small satellites range from CubeSats (10x10x10 cm units) to microsatellites (10-100 kg). Designing for minimal mass involves selecting lightweight materials and compact electronics.

Redundancy and Reliability ​

Space is a harsh environment with radiation, vacuum, and temperature extremes. Satellites must incorporate redundancy in critical systems to ensure continued operation despite failures. Reliability is achieved through rigorous component selection and testing.

A modular satellite design showing separate compartments for power, communication, payload, and propulsion systems, with labels indicating each module.

Structural Materials and Fabrication ​

Common Satellite Materials ​

  • Aluminum alloys: Lightweight, strong, corrosion-resistant; widely used for satellite frames and panels.
  • Titanium: High strength-to-weight ratio, used in critical load-bearing parts.
  • Carbon fiber composites: Extremely lightweight and strong; used for structural panels and booms.
  • Thermal blankets and coatings: Multi-layer insulation (MLI) made from aluminized Mylar or Kapton to protect against temperature extremes.

Material Sourcing and Processing ​

In a post-collapse scenario, sourcing aerospace-grade materials may be challenging. Alternatives include:

  • Recycling aluminum and titanium from scrap metal.
  • Producing carbon fiber composites from locally available carbon precursors (e.g., biomass-derived carbon fibers).
  • Fabricating thermal insulation layers using metallized films salvaged from electronics or packaging.

Fabrication Techniques ​

  • Machining: Milling, drilling, and turning metal parts using manual or CNC machines.
  • Sheet metal forming: Bending and shaping aluminum sheets for panels and brackets.
  • Composite layup: Hand-laying carbon fiber sheets with resin curing in simple molds.
  • Welding and fastening: Joining metal parts with TIG welding or mechanical fasteners.

Precision fabrication is essential to maintain structural integrity and fit components accurately.

A photo of a technician manually laying carbon fiber sheets onto a mold to create a satellite panel, illustrating composite fabrication.

Electronic Components and Assembly ​

Essential Satellite Electronics ​

  • Power subsystem: Solar panels, batteries, power regulators.
  • Communication subsystem: Transmitters, receivers, antennas.
  • Onboard computer: Microcontrollers or processors for command and control.
  • Sensors and payload: Cameras, spectrometers, magnetometers, or other mission-specific instruments.
  • Attitude control: Gyroscopes, reaction wheels, magnetorquers for orientation.

Component Sourcing and Manufacturing ​

Manufacturing advanced electronics from raw materials is highly complex. Practical approaches include:

  • Salvaging components from existing satellites, spacecraft, or terrestrial electronics.
  • Repairing and repurposing microchips, sensors, and circuit boards.
  • Producing simple printed circuit boards (PCBs) using manual etching and drilling techniques.
  • Assembling electronics by hand soldering and testing.

Integration and Wiring ​

Careful integration of electronic subsystems is critical. Wiring harnesses must be organized and shielded to prevent interference. Connectors and cables should be robust and space-rated.

A satellite’s electronic subsystem layout, showing solar panels connected to batteries, communication modules, and onboard computer with wiring paths.

Assembly and Integration ​

Cleanroom Environment ​

Satellite assembly requires a clean environment to prevent contamination of sensitive components. A basic cleanroom can be improvised using filtered air systems and strict protocols for personnel hygiene and clothing.

Mechanical Assembly ​

  • Mount structural components and panels.
  • Install electronic subsystems and payload instruments.
  • Connect wiring harnesses and secure cables.
  • Attach thermal insulation and protective covers.

Functional Testing ​

  • Power subsystem tests: Verify solar panel output and battery charging.
  • Communication tests: Check transmitter and receiver functionality.
  • Sensor calibration: Ensure payload instruments operate within specifications.
  • Software loading and verification on onboard computer.

A photo of engineers performing functional testing on a satellite in a cleanroom, using diagnostic equipment and computers.

Environmental Testing ​

Satellites must withstand the rigors of launch and space environment. Testing includes:

  • Vibration testing: Simulate launch stresses using vibration tables.
  • Thermal vacuum testing: Expose satellite to vacuum and temperature extremes.
  • Electromagnetic compatibility (EMC) testing: Ensure electronics do not interfere with each other.
  • Shock testing: Simulate mechanical shocks during launch and deployment.

In resource-limited settings, some tests can be approximated with improvised equipment, but critical tests should be prioritized to avoid mission failure.

A satellite undergoing vibration testing on a shaker table, with sensors attached to monitor structural response.

Launch Preparation and Deployment ​

Packaging and Transport ​

Satellites must be securely packaged to protect against mechanical damage and contamination during transport to the launch site.

Integration with Launch Vehicle ​

  • Mount satellite on deployer or adapter compatible with the rocket.
  • Verify electrical and mechanical interfaces.
  • Perform final system checks.

Deployment Mechanisms ​

Satellites often use spring-loaded or motorized deployment systems to release solar panels and antennas after reaching orbit.

Post-Launch Operations ​

  • Establish communication link.
  • Perform system checkouts.
  • Begin mission operations according to pre-planned schedules.

A photo of a small satellite mounted on a rocket payload adapter inside a cleanroom, ready for launch integration.

Practical Considerations for Post-Apocalyptic Satellite Manufacturing ​

Incremental Capability Building ​

Start with simple CubeSat-class satellites to develop manufacturing skills and infrastructure. Gradually increase complexity as resources and knowledge grow.

Collaboration and Knowledge Sharing ​

Pooling expertise across settlements and sharing designs, software, and manufacturing techniques accelerates progress.

Resource Management ​

Efficient use of scarce materials and recycling are essential. Prioritize critical components and avoid waste.

Training and Documentation ​

Maintain detailed records of designs, processes, and lessons learned. Train new technicians to sustain manufacturing capabilities.

Conclusion ​

Rebuilding satellite manufacturing is a challenging but achievable goal that enables humanity to regain space-based capabilities vital for communication, navigation, and scientific advancement. By focusing on modular design, accessible materials, careful assembly, and rigorous testing, survivors can produce functional satellites that support long-term recovery and expansion into space.

For foundational knowledge on materials and manufacturing techniques, see Materials for spaceflight and Advanced electronics manufacturing.

A completed small satellite orbiting Earth, with solar panels deployed and antennas extended, symbolizing successful manufacturing and deployment.