2 Design Process

2.1 Introduction

The process of designing and developing spacecraft is characterised by the fact that
it concerns single and “one-off” time product, that have to be produced within a
given amount of time.
Requirements of the principal and subsequent testing of test models lead to the
final design. This final design is then laid down in working drawings and other
documents, all of which define the final product or flight model.

2.2 Design criteria

Any design is led by the design criteria (mass, stiffness, shape, etc.). The proposal
phase is intended to leave room for negotiations on any alterations of the design
criteria. Depending on the kind of project, it may be necessary to derive further
specifications for subsystems, such as the solar arrays, from the design criteria.

2.3 Design specification

The first step of the design process is to derive the design specification. This needs
to comply with demands concerning:
• functioning with regard to primary tasks
• mechanical loads
• environmental influences
• material properties
• weight and balance
• reliability and lifetime

5
6 2 Design Process

• safety
• exchangeability, repairs and maintenance
• manageability
• interactions
Based on the design specification, a design and development plan is worked out
and work packages are defined. A work package describes the activities to be per-
formed, the available time and the resources available. It also includes the neces-
sary input and the expected output.

2.4 Design

Based on the design and development plan, the design specifications are further
tested and elaborated on during the design process by means of design studies,
computer simulations, analyses, trade-off studies, detailed testing, as well as
designing and testing test models.
During each step of the process the level of detail is increased in such a way
that, through design drawings, the design can be finalised in production documents
(drawings, manufacturing sheets), test plans and procedures.
Testing and studying certain aspects by means of test models form an important
part of the design process. These are not complete models. In most cases the fol-
lowing will be used:
• the structural model (SM, dynamic aspects)
• the thermal model (TM, thermal behaviour in vacuum)
• the electrical model (EM, the electrical behaviour of all systems combined and
in relation to the ground testing equipment or EGSE: Electrical Ground Support
Equipment)
• the qualification model (QM, qualification of the design for production of the
flight model, FM)
For the development of attitude control systems an attitude control model is
added.
Tests on the test models may lead to changes in the design. Deviations from the
design specifications need to be approved by the client.

2.5 Design control

The design process consists of several steps in which the design is laid down in
more detail. These steps are usually concluded with a number of reviews. In most
cases these are:
2.6 Exercises 7

• a preliminary design review (PDR) for the release of the preliminary design, in
general before starting production of the test models
• a critical design review (CDR) before the release of qualification and flight
models, preferably before the start of flight model production.

2.6 Exercises

2.6.1 Design and development

Find somewhere a design and development plan of ESA and NASA spacecraft.