Structural design optimization and FEM analysis validation for a 12U CubeSat

The increasing adoption of CubeSats for commercial and institutional missions has intensified the need for structurally efficient platforms capable of withstanding severe launch environments while maximizing usable mass and volume. This thesis presents the structural design optimization and finite element method (FEM) validation of a 12U CubeSat platform developed in collaboration with NPC Spacemind. Starting from an existing baseline configuration, the work aims to improve mass efficiency, structural performance, and manufacturability while ensuring compliance with CubeSat standards, launcher requirements, and internal industrial guidelines. An iterative design methodology is applied, combining requirement-driven geometric optimization with detailed numerical verification. The structural architecture is progressively refined to achieve improved load distribution and reduced mass without compromising stiffness or strength. A high-fidelity FEM model is developed to accurately represent mass properties, boundary conditions, and mechanical interfaces. The verification campaign includes model consistency checks, modal analysis, quasi-static load cases, and random vibration analysis based on launcher-derived environments. Structural adequacy is assessed using standard factors of safety and 3σ criteria for random vibration. The results demonstrate a meaningful reduction in structural mass compared to the baseline configuration while fully satisfying quasi-static and dynamic requirements. Random vibration analysis identifies conservative and bounding load cases, with stresses remaining within allowable limits. The validated design provides a robust and scalable structural solution, suitable for qualification and potential industrial adoption in future 12U CubeSat missions.