SatFab 3U CubeSat with Novel Phase Change Material Thermal Control System

The SatFab 3U CubeSat is an undergraduate student-led project at the University of Maryland, aiming to develop a complete CubeSat from scratch. This mini satellite, approximately the size of a small loaf of bread (10x10x30 cm), is designed to house cutting-edge thermal management technology and a custom-made GPS. The core innovation is a novel phase change material (PCM)-based thermal control system, which is simpler, less expensive, and less energy-intensive than existing cooling mechanisms. This system utilizes PCMs that store and release large amounts of energy during phase transitions (solid to liquid and vice versa) to regulate satellite electronics temperatures. When the satellite is in sun-view, the PCM absorbs heat and transitions from solid to liquid, maintaining a steady temperature. When temperatures drop in Earth’s shadow, the material solidifies and releases stored heat back to the electronics, ensuring optimal performance and extended longevity by minimizing temperature fluctuations. The team is designing and building every component, including the exterior shell and communication system. The project aims for a launch in late 2027 or early 2028 through NASA’s CubeSat Initiative, which will send CubeSats to the International Space Station before releasing them into lower Earth orbit. The team is also working with partners like aerospace firm Amphenol CIT to ensure professional reliability standards and plans to test components via balloon payloads to simulate flight conditions.