A method for thermally stabilizing a communication satellite in orbit around the Earth relies on the discrete rotational symmetry of the pattern of antenna beams of the satellite. Exploiting the symmetry, the orientation of the satellite is changed from time to time by rotating the satellite through a symmetry angle of the rotational symmetry. Because of the symmetry, the beam pattern is unchanged after the rotation; but, because the rotation angle is less than 360°, a different side of the satellite is exposed to sunlight. The use of different thermal radiators and thermal shields on different sides of the satellite means that the thermal budget of the satellite is different after the rotation. By judiciously applying rotations as needed, as the orbit's orientation relative to the Sun evolves in time, it is possible to achieve effective control on the thermal budget of the satellite.

A method for thermally stabilizing a communication satellite in orbit around the Earth relies on the discrete rotational symmetry of the pattern of antenna beams of the satellite. Exploiting the symmetry, the orientation of the satellite is changed from time to time by rotating the satellite through a symmetry angle of the rotational symmetry. Because of the symmetry, the beam pattern is unchanged after the rotation; but, because the rotation angle is less than 360°, a different side of the satellite is exposed to sunlight. The use of different thermal radiators and thermal shields on different sides of the satellite means that the thermal budget of the satellite is different after the rotation. By judiciously applying rotations as needed, as the orbit's orientation relative to the Sun evolves in time, it is possible to achieve effective control on the thermal budget of the satellite.

A structural spacecraft component comprising internal microstructure; wherein said microstructure comprises a plurality of parallel layers and a plurality of spacers that connect adjacent parallel layers; wherein said structural spacecraft component is a product of an additive manufacturing process.

A structural spacecraft component comprising internal microstructure; wherein said microstructure comprises a plurality of parallel layers and a plurality of spacers that connect adjacent parallel layers; wherein said structural spacecraft component is a product of an additive manufacturing process.

A lightning protector device for laying on a structure that is to be protected the device comprises: a surface coating including at least one conductive paint layer. A plurality of electrically conductive elements is arranged in spaced-apart manner on the structure, and the elements are in contact with the conductive paint layer. A protective coating is arranged on the surface coating and comprises a material that is thermally insulating and electrically conductive. The protective coating covers the electrically conductive elements in part.

A lightning protector device for laying on a structure that is to be protected the device comprises: a surface coating including at least one conductive paint layer. A plurality of electrically conductive elements is arranged in spaced-apart manner on the structure, and the elements are in contact with the conductive paint layer. A protective coating is arranged on the surface coating and comprises a material that is thermally insulating and electrically conductive. The protective coating covers the electrically conductive elements in part.

A method for building an aerodynamic structure, an aerodynamic structure, and a vehicle that includes the aerodynamic structure are provided. The method includes providing a structure with at least one substantially-flat exterior surface. The method also includes attaching blocks of rigid fibrous insulation to the at least one substantially-flat outer surface of the structure. Outward-facing surfaces of the blocks of rigid fibrous insulation extend past a target outer mold line of a final aerodynamic shape. The method also includes machining the outward-facing surfaces of the attached blocks to the outer mold line.

A method for building an aerodynamic structure, an aerodynamic structure, and a vehicle that includes the aerodynamic structure are provided. The method includes providing a structure with at least one substantially-flat exterior surface. The method also includes attaching blocks of rigid fibrous insulation to the at least one substantially-flat outer surface of the structure. Outward-facing surfaces of the blocks of rigid fibrous insulation extend past a target outer mold line of a final aerodynamic shape. The method also includes machining the outward-facing surfaces of the attached blocks to the outer mold line.

A method of making a thermal control coating is provided. A primer layer can be applied to a substrate to form an exposed surface. The primer layer can include an epoxy binder and a silica filler. The exposed surface can be treated with an oxygen plasma to form a treated surface. A silicate-based thermal control coating can be applied to the treated surface, for example, by spraying, to form a thermal control coating on the substrate. Spacecraft and spacecraft hardware components coated with the thermal control coating, are also provided.

A method of making a thermal control coating is provided. A primer layer can be applied to a substrate to form an exposed surface. The primer layer can include an epoxy binder and a silica filler. The exposed surface can be treated with an oxygen plasma to form a treated surface. A silicate-based thermal control coating can be applied to the treated surface, for example, by spraying, to form a thermal control coating on the substrate. Spacecraft and spacecraft hardware components coated with the thermal control coating, are also provided.