Production of Flight Instruments for Multi-Satellite Constellations

Recent National Academy of Science Decadal Surveys in space and Earth-science have called for simultaneous, distributed multi-point measurements in and from space, requiring constellations of small spacecraft. Small satellites have demonstrated their utility for enabling high-quality science measurements and observations. NASA missions have leveraged advances in sensor miniaturization, technology innovations, and new small satellite mission architectures to enable meaningful measurement-based scientific investigations that operate on small satellites and that are responsive to science objectives described in National Academy of Science Decadal Surveys. The advent of high capability small spacecraft enables consideration of science missions involving multiple small spacecraft, constellations of a few or many for simultaneous distributed in situ observations or remote observations from a variety of viewpoints. The central challenge for fielding instrumented space-flight constellations is to provide the required multiple sets of fully verified and calibrated instrument hardware, software, and operational processes from within a one-off project-based scientific space flight culture. Although there are numerous commercial entities providing “off-the shelf” spacecraft and avionics, the challenge lies in the multi-unit production of the uniquely targeted instrumentation necessary to perform the specific measurements required for a particular science investigation. Traditionally, the cost of such instrumentation has represented a significant portion of the hardware cost for a mission and posed the highest risk area for implementation. A shift in paradigm from large science platforms to constellations of smaller satellites drives the challenge to build instruments in a quasi-production environment. This paper describes key aspects of, and challenges encountered in the development program for the successful production of instruments for the Fast-Plasma Investigation (FPI) instrument suite of 64 flight plasma spectrometers and supporting electronics on the NASA Magnetospheric Multiscale (MMS) 4 satellite constellation mission. Although the MMS mission was not composed of small satellites, there are key aspects of the instrument production that apply directly to constellations of small satellites.