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By now, the detailed system design has been finalized. Some elements of the system have been prototyped and subjected to some tests as part of the iterative development process. In this phase, the fabrication of the flight model of the system is carried out. Followed by this, the system is [[Introduction to Mechanical Subsystem#Integration | integrated]] and then subjected to [[Various Tests performed on Integrated Satellite | system-level tests]] before clearing it for launch.
==Procurement of Materials==
==Manufacturing==
Since a manufacturing plan is ready, one can start looking out for manufacturers parallelly while procuring materials. To manufacture different parts, different processes need to be employed. So, manufacturers should be chosen accordingly as there is a low possibility that a single manufacturer cannot can cater to all our requirements. The tolerances must be decided, and a check should be performed with the manufacturers whether the manufacturing can be done in accordance with it or not. Further, manufacturability of all the parts needs to be checked with the manufacturer. The design files need to be verified with manufacturers. Certain recommendations might be received from the manufacturer like the addition of fillet or chamfers at the edges to the parts. Once the things mentioned above have been completed, the parts of the system are manufactured. Post manufacturing, a check should be done to see if the parts are manufactured as per the requirements.<br> <br/>For space systems, usually, two models are manufactured -
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# Flight Model - This is the model which is launched into space and implements the mission. The flight model is subjected to specific tests before the launch.
# Qualification Model - It is a replica of the flight model, which is used for qualifying the space system before the actual flight model is made. The qualification model is passed through more rigorous tests than the flight model to check if the system design is appropriate to be launched into space. If not, the faults in the system are identified and the required changes are made.
==Integration==
Integration is one of the main aspects of satellite design and engineering. It’s quite complex as numerous electrical, mechanical components work together to achieve a challenging objective. Understanding of the system plays a key role in designing an efficient and easier way to integrate the components, functions, subsystems into a full-fledged system and to ensure functional integrity. Functional tests are done prior to integration to check that the components work when assembled together. Documentation is necessary to show that every single component, nut, bolt, wire is compatible with space flight and assembled using proper procedures. Integration and testing often go simultaneously. It is very necessary to draft an integration sequence based on various integration practices. Real or prototyped hardware must be used for practicing the integration.
# Component level testing- Tests performed on individual components which assemble together to form parts of the subsystem. (E.g: Solar panel)
# Subsystem level testing- Tests performed on subsystems which are formed by assembly of components. (E.g: Communication subsystem)
# System level testing- Tests conducted on the entire satellite/ space system which is formed after integration of all subsystems. [[File:production_phaseSystems Engineering Life Cycle - V Model.pngPNG|650px|center]]
# Qualification testing- Tests are performed to show that the design, manufacturing, testing, functions, meet the mission requirements. These tests are performed on the Qualification Model (QM). The boundary conditions applied in these tests are severe and do exceed the design safety parameters than the actual scenario to check the sustainability of the system.
# Acceptance testing- These tests are performed on the complete integrated system to be sent in orbit. The objective of these tests is for quality assurance of materials, parts and possible errors in integration along with the specific requirements of the system. However, these test limits are moderate and do not exceed the design safety parameters causing failures in the system.
Once the various tests have been performed on the QM and FM, celebrate! Because your satellite is now ready to be launched.
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If you are done reading this page, you can go back to [[Starting a Student Satellite Project]].
