Launch-Load Structural Assessment of a 1U Al 6061-T6 CubeSat Frame: A Review of Finite Element Modal, Static and Random Vibration Practice with Supporting Simulation Results

Abstract

CubeSats have become a widely adopted platform for low-cost space missions, yet their compact 10 cm × 10 cm × 10 cm envelope leaves little margin for structural error under the severe mechanical and thermal loads of launch and orbital operation. Nanosatellites are structurally most at-risk during launch, when they face quasi-static acceleration and broadband random vibration while mounted in a deployer. This paper surveys how finite element analysis is used to qualify 1U CubeSat structures for these conditions, limited to three analysis types: modal (eigenfrequency) extraction, static structural loading and random vibration based on power spectral density (PSD). The survey covers common modelling choices, including material selection, meshing, constraint idealization, load definition and acceptance criteria such as minimum fundamental frequency, stress margin against yield and 3? response limits. To show how these practices work in use, a 1U frame of aluminium 6061-T6 was modelled in SolidWorks and analyzed in ANSYS Workbench with the base fixed. The modal solution gave twelve modes between 539.67 Hz and 1076.3 Hz, well above the stiffness thresholds usually quoted by launch providers. Under a 650 N static load, the peak deflection was 0.3769 mm and the maximum von Mises stress was 65.66 MPa, about a quarter of the 276 MPa yield strength. The random vibration run, pre-stressed by the modal solution, produced a smooth response PSD with its highest value at the 20 Hz lower bound of the input spectrum and no resonant amplification. Taken together, the review and the results show that the frame is stiff and structurally sound for launch. The paper also highlights common gaps in the literature, such as inconsistent boundary conditions and incomplete reporting of PSD inputs.

Introduction

The text presents a study on the structural design and finite element analysis (FEA) of a 1U CubeSat frame using SolidWorks and ANSYS Workbench. It focuses on evaluating the structural strength, stiffness, and vibration behaviour of a CubeSat under launch conditions.

CubeSats are small, standardized satellites measuring 10 × 10 × 10 cm for a 1U configuration, with a maximum mass of approximately 1.33 kg. Their compact size and low launch cost make them suitable for educational, scientific, commercial, and defence missions. However, their lightweight structures must withstand severe mechanical loads, vibrations, and acceleration during rocket launch.

The study focuses on three major structural analyses:

1. Modal Analysis: Determines the natural frequencies and mode shapes of the CubeSat structure to identify possible resonance problems during launch.

2. Static Structural Analysis: Evaluates deformation, strain, and von Mises stress under applied loads to ensure that the structure remains within the material's strength limits.

3. Random Vibration Analysis: Examines the structural response to random launch vibrations using Power Spectral Density (PSD) acceleration inputs and evaluates the resulting 3σ stress and deformation.

Objectives of the Study

The main objectives are to:

• Review existing research on modal, static structural, and random vibration analyses of CubeSat structures.

• Identify important modelling parameters, including material selection, meshing, boundary conditions, loading, and acceptance criteria.

• Develop a 1U CubeSat frame using Aluminium 6061-T6.

• Determine natural frequencies and mode shapes.

• Evaluate displacement, strain, and von Mises stress under static loading.

• Analyse random vibration responses and identify possible resonant amplification.

• Compare the simulation results with previously published research.

Design and Material Selection

The study considers a 1U CubeSat frame with the following specifications:

Aluminium 6061-T6 was selected because of its high strength-to-weight ratio, good machinability, toughness, availability, and compatibility with aerospace structural applications.

Methodology

The structural analysis follows a systematic design and simulation process:

1. 2D Modelling: Front, top, and bottom views were prepared according to the 1U CubeSat dimensions and design specifications.

2. 3D Modelling: The CubeSat frame was developed in SolidWorks using parametric modelling techniques.

3. ANSYS Import: The completed 3D model was imported into ANSYS Workbench for finite element analysis.

4. Meshing: The geometry was discretized using first-order tetrahedral elements with a default element size of 5 mm.

5. Boundary Conditions: Appropriate supports, forces, and vibration inputs were assigned according to the requirements of each analysis.

6. Finite Element Analysis: Different structural and thermal analyses were performed to evaluate the overall performance of the CubeSat.

Mesh Statistics

The final finite element mesh contained:

• Number of nodes: 112,957

• Number of elements: 64,342

• Degrees of freedom: 338,871

• Element type: First-order tetrahedral elements

• Default element size: 5 mm

Analyses Performed

The overall ANSYS project included nine types of analysis:

1. Modal analysis.

2. Static structural analysis.

3. Eigenvalue buckling analysis.

4. Random vibration (PSD) analysis.

5. Harmonic response analysis.

6. Response spectrum analysis.

7. Transient structural analysis.

8. Transient thermal analysis.

9. Fatigue life analysis.

However, the main paper specifically focuses on modal, static structural, and random vibration analyses.

Limitations

The study uses a linear finite element model of the bare CubeSat frame. Internal components, fasteners, and deployer contact behaviour are not included. Furthermore, the simulation results have not been experimentally validated through physical vibration or static testing. Therefore, the results represent a preliminary design assessment rather than final launch qualification.

Conclusion

This paper reviewed how modal, static structural and random vibration analyses are used to assess 1U CubeSat frames for launch, and it applied those practices to an Al 6061-T6 frame modelled in SolidWorks and analyzed in ANSYS Workbench. The review found that the three analyses are well established for early structural checks. It also found that published studies differ widely in constraints, load definitions and PSD reporting, which makes direct comparison difficult. Within the limits of a linear model of the bare frame, the Al 6061-T6 1U structure is stiff and strong enough for the launch conditions considered. It meets the usual frequency criterion by a wide margin and stays far below yield under the static load, and its random vibration response shows no sign of resonant amplification. These results show that geometry is a sound starting point for detailed design. They do not qualify the structure for flight.

References

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Copyright

Copyright © 2026 Prabhudev G E, Dr. H.C. Chittappa, Dr. Badari Narayan, Dr. Guled F D. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.