Modular Interface Design and Trade Study for a Rapid Deployment CubeSat

Abstract

Between 2000 and 2024, a large number of small satellite missions fell short of their goals, with NASA pointing to structural and integration issues as common causes. Building satellites faster and at lower cost has become a major goal, especially as space systems grow more complex. Modular designs have emerged as one way to meet this demand, but the lack of reliable, reusable structural connections has limited progress. To better understand the trade-offs, this work looked at four connection methods for CubeSats: solenoid latches, rack systems, Wedge-Lok clamps, and screw fittings using L-shaped rails. Each one was reviewed using weighted criteria such as readiness for flight, expected weak points, physical size, and assembly ease. The screw and Wedge-Lok types came out ahead, mostly because of their simplicity and proven use in past missions. They also show promise for teams looking to simulate system performance before launch. Designs that allow last-minute changes, support system integration, and enable compatibility with digital models are especially useful as engineering shifts toward virtual prototyping and model-based development. The process used here can help teams decide on mechanical interfaces based on actual performance needs, not just legacy or convenience. What sets this work apart is the clear method it provides for selecting structural options that match modern space project demands. The main contribution is a flexible, criteria-driven approach for choosing CubeSat interface hardware suited to modular builds and digital system modeling.