Mission Readiness
Connect POE concepts to aerospace systems, establish engineering documentation expectations, and complete the required PPE/FabLab safety work.
POE Unit 0
Engineering Readiness & CubeSat Lightweight Structure Challenge
Unit mission: Use engineering documentation, safety, CAD, additive manufacturing, laser cutting, and assembly skills to build the lightest 4-inch CubeSat structure that can pass every qualification requirement.
Unit Structure
Foundation → CubeSat Project
Lessons 0.1–0.3 establish the POE systems, documentation, and safety foundation. Lessons 0.4–0.10 apply those skills to one continuous CubeSat engineering challenge.
Define → Select → CAD
Create the design brief, generate and evaluate structural concepts, then turn the selected idea into a complete manufacturable CAD assembly.
Manufacture → Assemble → Compete
Optimize the printed frame and acrylic plates, complete the relevant certifications, assemble with M3 hardware, and qualify the final structure.
Project Brief
CubeSat Lightweight Structure Challenge
Design freedom exists inside a deliberately narrow solution space so teams can begin engineering immediately.
| Requirement | Specification |
|---|---|
| Competition objective | Lightest fully assembled structure that passes every qualification requirement wins. |
| Maximum external size | 4 in × 4 in × 4 in, including all hardware. |
| Top + bottom | Laser cut from the team’s single 4 in × 12 in × 1/8 in acrylic sheet. |
| Sides | Open; side panels are not permitted. |
| Primary frame | 3D printed using the same teacher-selected filament material for every team. |
| Assembly | M3 screws for primary structural connections; no structural adhesive. |
| Serviceability | Structure can be disassembled and reassembled with normal hand tools. |
| Print documentation | Layer height, wall/perimeter count, infill %, infill pattern, print orientation, estimated print time, and estimated filament use. |
| Qualification load | Support a standardized 10 lb vertical load for 30 seconds using the teacher-provided load plate without fracture, separation, or visible permanent deformation. |
| Official mass | Includes acrylic, printed frame, M3 hardware, inserts/nuts/washers, and all permanent components; measured to 0.1 g. |
Lesson Map
Unit 0 Lessons
The project begins in Lesson 0.4 and advances one required milestone each day through the final competition.
| Lesson | Title | Success Target | Evidence | Open |
|---|---|---|---|---|
| 0.1 | Engineering for the Mission | Classify aerospace systems and connect POE concepts to mission needs. | Engineering for the Mission worksheet: system analysis, mission connections, and decision defense | Open LessonPPTX |
| 0.2 | Engineering Notebook & Documentation Refresher | Create records that another engineer can follow and reproduce. | Complete engineering notebook setup entry | Open LessonPPTX |
| 0.3 | PPE and FabLab Safety | Control hazards before project work begins. | PPE and FabLab safety certification evidence | Open LessonPPTX |
| 0.4 | CubeSat Challenge: Define & Design | The design brief captures the fixed rules and each sketch clearly shows how the acrylic plates, printed frame, and M3 connections work together. | CubeSat Design Brief + 3 annotated concept sketches | Open LessonPPTX |
| 0.5 | Evaluate & Develop | The selected concept is supported by evidence-based scoring and includes enough dimensions and connection detail to begin CAD. | Decision Matrix + selected concept + detailed annotated sketch | Open Lesson |
| 0.6 | CAD & Assembly Design | The CAD model fits inside 4 in × 4 in × 4 in, preserves open sides, uses 1/8 in acrylic top/base plates, and shows all M3 assembly interfaces. | Complete CAD assembly + CubeSat design check | Open Lesson |
| 0.7 | Additive Manufacturing | The frame is printable, uses the class-standard filament, and all required slicing settings are documented before production. | 3D Printer Certification verification + print settings record + print-ready frame files | Open LessonPPTX |
| 0.8 | Laser Manufacturing | Both required plates fit on the single 4 in × 12 in × 1/8 in acrylic sheet, include M3 interfaces, and are approved before cutting. | Laser Cutter Certification + 4 in × 12 in cutting layout + laser-ready files | Open Lesson |
| 0.9 | Fabrication & Assembly | The CubeSat is fully assembled with M3 screws, remains within the 4-inch envelope, has open sides, and is ready for qualification. | Hand Tools Certification + completed CubeSat structure | Open Lesson |
| 0.10 | CubeSat Lightweight Structure Competition | The structure passes every required check before weigh-in, and the team can connect its final mass and performance to specific design decisions. | Final CubeSat + qualification record + official mass + short engineering design review | Open Lesson |
Competition Logic
Strong Enough, Then Lightest
Meet the architecture
4-inch maximum cube, open sides, laser-cut acrylic top/base, printed frame, and M3 structural assembly.
Pass qualification
Dimension, construction, load, and assembly-integrity checks are pass/fail.
Weigh the survivors
Only structures that qualify receive an official mass. Lowest qualified mass wins.