This study explores the development of lattice-based panels for satellite applications using Direct Metal Laser Sintering and aimed to optimize lightweight, high-strength structures suitable for CubeSat deployment. Three lattice configurations namely Body-Centered Cubic, Octet, and Gyroid were evaluated. While Gyroid lattices exhibited the highest compressive strength at 13,825.8 N, the BCC lattice was selected for the final design due to superior manufacturability and weight reduction potential. The final optimized panel weighed 185.7 g, achieving an 11.4% reduction from the initial rib-type design and a 65.2% reduction from a solid panel. Finite Element Analysis and mechanical testing confirmed that the fabricated structures met the necessary mechanical requirements for aerospace launch conditions.

This study explored the development of lattice-based panels for satellite applications using Direct Metal Laser Sintering and aimed to optimize lightweight, high-strength structures suitable for CubeSat deployment. Three lattice configurations, namely Body-Centered Cubic, Octet, and Gyroid, were evaluated. While Gyroid lattices exhibited the highest compressive strength at 13,825.8 N, the BCC lattice was selected for the final design due to superior manufacturability and weight reduction potential. The final optimized panel weighed 185.7 g, achieving an 11.4% reduction from the initial rib-type design and a 65.2% reduction from a solid panel. Finite Element Analysis and mechanical testing confirmed that the fabricated structures met the necessary mechanical requirements for aerospace launch conditions.