Development of a predictive method of the response to shock loads of a spacecraft's structure

This thesis addresses one of the most pressing challenges in satellite development: accurately predicting shock loads during launch to optimize structural design and reduce the need for costly and time-consuming testing. As satellites are exposed to severe dynamic loads from rocket stage separations and pyrotechnic events, en- suring resilience against these forces is crucial for mission success. Traditional em- pirical methods for shock load prediction often rely on conservative assumptions, leading to over-design and added costs. This research, conducted in collaboration with SITAEL SpA and supported by insights and tools from the European Space Agency (ESA), introduces a novel methodology for more precise shock load predic- tion. The proposed model, based on modal decomposition and transfer function analysis, enables engineers to calculate shock transmissibility from low to high fre- quency spectrum, overcoming the limitations of empirical methods. The method- ology was initially validated through simulations on simple 2-DOF systems and subsequently applied to the complex ShockSat case study, an open-source satel- lite project by NASA. Simulations carried out during a research period at ESA provided critical industry insights and further refined the model’s accuracy and practical relevance. These simulations revealed the model’s capability to predict shock responses in real satellite structures, offering potential design optimizations to mitigate shock effects. While experimental validation remains a future goal, this thesis establishes a robust foundation for advancing shock analysis in aerospace engineering. By shifting away from conservative assumptions toward more accu- rate prediction, the research holds promise for reducing dependency on extensive physical testing, ultimately leading to more efficient and sustainable satellite de- velopment. As the space industry places greater emphasis on cost-effectiveness and reliability, this predictive shock model meets the needs of today’s market, opening up new possibilities for building more resilient spacecraft and making the design process more efficient.