Preliminary Design and Analysis of an FDM Payload Unit for HAB Missions

The study, situated within the context of high-altitude balloon (HAB) missions commonly employing materials like acrylic, aluminum, or polystyrene, aims to determine the optimal material choice between acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) for HAB missions through mechanical testing and thermal analysis. Employing thermal transfer analysis in ANSYS software, this research focuses on the preliminary design and thermal assessment of a Fused Deposition Modeling (FDM) payload unit for near-space missions, evaluating three models for their unique structural advantages and enhancement potential. Investigating the thermal properties of ABS and PLA for payload structure, the research seeks materials capable of withstanding extreme near-space conditions while optimizing structural integrity and weight to enhance payload unit performance and reliability. The study’s outcomes provide valuable insights for final interior component design and integration, contributing to the development of resilient and efficient payloads for future near-space missions.