Pass first. Then weigh in.
Structural qualification is pass/fail. Among the structures that pass every requirement, the lowest total assembled mass wins.
POE Unit 0 • Lesson 0.6
CAD & Assembly Design
Focus question: How do we turn the selected CubeSat concept into a manufacturable assembly that fits the 4-inch envelope?
Challenge Rules
CubeSat Lightweight Structure Challenge
Every team works inside the same architecture and material limits. Your engineering advantage comes from how efficiently you use them.
- Maximum assembled envelope: 4 in × 4 in × 4 in, including hardware.
- Top and bottom: laser cut from the team’s single 4 in × 12 in × 1/8 in acrylic sheet.
- Sides: remain open; no side panels.
- Primary frame: 3D printed using the same teacher-selected filament material for every team.
- Assembly: M3 screws for all primary structural connections; structural glue is not permitted.
- Serviceability: the structure must be able to be disassembled and reassembled with normal hand tools.
- Competition: the lightest structure that passes every qualification requirement wins.
Lesson Targets
What You Will Be Able to Do
I can model the complete CubeSat assembly, verify the design envelope, and design accessible M3 connections between printed and laser-cut parts.
Complete CAD assembly + CubeSat design check
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.
Activity Flow
How Today Advances the CubeSat
1. Build the reference envelope
Model or verify the 4 in cube and 1/8 in plate thickness.
2. Model the assembly
Create the printed frame and laser-cut plate components in their assembled positions.
3. Complete a design check
Verify envelope, M3 access, open sides, clearances, and manufacturing readiness.
Design Gate
Do Not Manufacture Until These Checks Pass
Nothing—including screw heads or connection features—extends beyond the maximum 4-inch cube.
Every M3 screw can be installed and removed with reasonable tool access.
Printed parts have realistic wall thicknesses and acrylic parts can be cut from the assigned stock.
Project Milestone
Today’s Required Deliverable
CAD Assembly v1 + Design Check
- Complete CubeSat assembly modeled in CAD.
- Top and bottom represented as 1/8 in acrylic components.
- 3D-printed frame represented as separate manufacturable component(s).
- M3 screw locations and connection features modeled.
- All external geometry fits inside the 4 in × 4 in × 4 in envelope.
- Screenshot or inspection view demonstrating the open-side architecture.
Engineering Decision
Document the Reasoning
What did your team decide today?
What measurements, requirements, comparisons, calculations, or manufacturing information support that decision?
Why does that evidence make the decision appropriate for a lightweight structure that still has to qualify?
Resources
Lesson Resources
CubeSat Unit 0 Overview
Review the complete challenge sequence, project rules, deliverables, and competition objective.
Principles of Engineering
Return to the POE hub for units, course resources, and certifications.