Affordable identification and modelling of uncertain design specifications when introducing new technologies in space applications

Doctoral thesis, 2021

When introducing new technologies in space products, both the uncertainties regarding technology feasibility and the way in which the technology affects the product development process hinder the early establishment of appropriate engineering specifications. Failing to establish product specifications during conceptual stages leads to problems discovered during later phases of the product development process, when design and process changes are the most expensive.

This thesis proposes a digital holistic design platform and a method of constraints replacement for a cost- and time-efficient identification of specification uncertainties when designing space products with new technologies. The digital platform and methods have been developed and tested through industrial case studies featuring the introduction of new technologies for on-orbit applications. Most of these studies were performed in the context of, but are not limited to, the introduction of additive manufacturing.

The platform and proposed constraints replacement method are based on function modeling strategies (for modeling product architecture and requirements during conceptual design phases), coupled with activity modeling strategies (for modeling the impact of product architecture on product development schedules and costs). The platform and method enable the identification and assessment of unknown uncertainties, thereby reducing the likelihood of expensive redesign processes during later development phases.

Moreover, they enable the inclusion of multidisciplinary design trade-offs during conceptual stages and encourage the establishment of a culture of uncertainty seeking and effective data documentation and transfer.