Design and Manufacturing of Extremely Low Mass Flight Systems

Extremely small flight systems pose some unusual design and manufacturing challenges. The small size of the components that make up the system generally must be built with extremely tight tolerances to maintain the functionality of the assembled item. Additionally, the total mass of the system is extremely sensitive to what would be considered small perturbations in a larger flight system. The MUSES C mission, designed, built, and operated by Japan, has a small rover provided by NASA that falls into this small flight system category. This NASA-provided rover is used as a case study of an extremely small flight system design. The issues that were encountered with the rover portion of the MUSES C program are discussed and conclusions about the recommended mass margins at different stages of a small flight system project are presented.