Fabrication and Testing of a PowerSphere Engineering Development Unit

During the past three years the team of The Aerospace Corporation, Lockheed Martin Space Systems, NASA Glenn Research Center, and ILC Dover LP have been developing a multifunctional inflatable structure for the PowerSphere concept under contract with NASA (NAS3-01115). The PowerSphere attitude insensitive solar power-generating microsatellite, which could be used for many different space and Earth science purposes as discussed elsewhere, is ready for further refinement and flight demonstration. The project culminated during the third year with the manufacturing of the Powersphere Engineering Development Unit (EDU). One hemisphere of the EDU system was tested for packing and deployment and was subsequently rigidized. The other hemisphere was packed and stored for future testing in an uncured state. Both cured and uncured hemisphere components were delivered to NASA Glenn Research Center for thermal cycle testing and long term storage respectively. This paper will discuss the design, manufacturing, and thermal cycle testing of the PowerSphere EDU. The program also had a significant Education Outreach segment that will also be discussed.