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Reaching New Heights: FreeFall’s Antennas Integral to SmallSat Communications on CatSat Mission

FreeFall Aerospace has achieved a milestone with its innovative antenna systems, which are now operational on CatSat, a significant NASA CubeSat Launch Initiative project. Launched July 4th in partnership with the University of Arizona, the mission, led by Principal Investigator Dr. Walker and FreeFall Senior Engineer Dr. Aman Chandra, is a technological and educational demonstration. It comprises multiple FreeFall-designed antennas, each addressing unique mission needs.

We spoke with Terrance Pat, an RF Design Engineer, to learn more about FreeFall’s three unique antennas designed for CatSat.

Can you briefly describe each unique antenna that FreeFall designed for CatSat?

“The first, an inflatable X-band spherical antenna, enables rapid data downlink while demonstrating advanced inflatable antenna technology. The highlighted technology of the CatSat mission—This Mylar antenna, compactly stowed for launch, unfolds in orbit to provide a large, high-gain aperture that dramatically enhances data return.

The second is a patch antenna solution. We have two of these patch antennas onboard the spacecraft. One was designed for the X-band to serve as the backup downlink solution, and the other was intended for the C-band to act as a radio beacon to be detected by ham radio operators worldwide.

The third antenna developed by FreeFall is the HF whip antenna for the WSPR experiment, which utilizes amateur radio stations worldwide to study the conditions of the ionosphere and accomplish the mission’s pedagogical aspects.”

Were any novel engineering techniques or concepts applied to improve antenna performance?

“We had to carefully design the feed for the inflatable spherical high-gain antenna. We needed to account for how the RF electronics payload would be positioned concerning the reflector. Therefore, the line feed design was developed and rigorously optimized to minimize spherical aberration while considering the deployment’s payload positioning and mechanical aspects. Our access to the ANSYS HFSS software greatly aided this design work.”

FreeFall Aerospace’s 10GHz Patch Antenna

For the patch antenna, the challenge was developing a solution that produced circular polarization to maximize the spacecraft’s downlink capability regardless of how it was oriented with respect to the 6.1m ground stations dedicated to picking up X-band signals from CatSat. From a design standpoint, most work focused on optimizing the interactions between the internal structure inside the patch and external features designed to produce circular polarization. Again, the ANSYS software greatly aided in this design work.

The HF whip antenna had to be designed to cover all the bands that ham radio operators utilized with the WSPR protocol and network. Therefore, its length was critical for correct operation, and we utilized established amateur radio rules of thumb and engineering practices to complete the design work. Also, the design process involved constant communication between the RF and mechanical teams to account for the deployment’s electrical and mechanical aspects to minimize risk and unexpected outcomes.

In addition, FreeFall designed the physical structure of the HF whip antenna and deployer. At the same time, Rincon Research was responsible for developing the HF upconverter electronics to optimize the throughput and X-band downlink of WSPR data for post-processing and scientific dissemination of the WSPR ionosphere experimental results. Their contribution was crucial to the success of the CatSat mission.

What testing phases were critical to ensure each antenna would perform reliably in orbit?

The most crucial test phases for validating the antennas to work in orbit are thermal-vac, vibe, and shock. These rigorous tests ensure the resilience and reliability of the antennas in the harsh conditions of space, providing reassurance to all stakeholders.

CatSat Continues:

Operating in low-Earth orbit, CatSat orbits Earth 15 times daily, relaying high-definition imagery and conducting ionospheric studies. The mission, led by Principal Investigator Dr. Walker and FreeFall Senior Engineer Dr. Aman Chandra, is not just a technological feat but also an inspiring educational demonstration that we can all support.

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The Emerge Accelerator is a 12-week program to propel venture creation and accelerate technology transition. It brings together DoD mission partners and emerging technology teams. What sets the NSIN Emerge Accelerator apart is its focus on facilitating collaboration between cutting-edge companies and top research universities. FreeFall’s Aman Chandra, Ph.D., is not only a University of Arizona alum but also leads our effort in this accelerator as our Senior Engineer for Aerospace Systems R&D.

FreeFall looks forward to leveraging this opportunity to pursue federal and commercial markets and strengthen our capabilities for doing business with the federal government and private sector.

“This journey wouldn’t be possible without the support of our incredible team, partners, the University of Arizona, and the NSIN – National Security Innovation Network community. We are excited about the possibilities and committed to making a lasting impact in satellite communications.”- Julie Bonner, Director of Communications

NSIN Official Press Release

The Emerge Accelerator connects DoD mission partners with emerging technology teams and startups at our nation’s top research universities.

Cutting-edge companies will demonstrate how intellectual property from top research universities can be commercialized for dual-use, civilian, and military markets during the next cohort of National Security Innovation Network (NSIN)’s Emerge Accelerator program.

The 12-week program offers participants funding to accelerate venture creation and technology transition. The program also offers access to feedback, advisors, and potential partners from the DoD and private industry. While pursuing federal and commercial markets is highly encouraged, the NSIN Emerge Accelerator excels at providing new ventures with the tools necessary to do business with the federal government and the private sector.

13 companies representing 13 unique academic institutions were accepted into the 2024 NSIN Emerge Accelerator. The teams have reached a Technology Readiness Level(TRL) of 4 (validation in a relevant environment) or greater, and have a technology vertical focus on artificial intelligence/machine learning (AI/ML), deep tech, autonomy, cyber security, and other general technology solutions.

Meet the 2024 Emerge Accelerator Cohort

ARMADA Marine Robotics, Inc.

Academic Institution: Woods Hole Oceanographic Institution (WHOI)

ARMADA provides industry and the government with an innovative hardware platform and a cost-efficient operations model that will revolutionize in situ ocean monitoring at scale.

Covert Defenses

Academic Institution: Purdue University

Covert Defenses enables zero-downtime operation of industrial control systems in cyber-contested environments. Their solution allows for continuous operations, even if penetrated by an insider.

EMP Technology Solutions

Academic Institution: University of Texas at Dallas

EMP Technology Solutions has developed a system for radioisotope identification that is portable, scalable, modular, and network-compatible. Their system works quickly, detecting and identifying radioactive threats in about five seconds.

Fourier LLC

Academic Institution: Northeastern University

Fourier is commercializing the breakthrough platform technology of thermoformable technical ceramics. The company is bringing large-scale production to the manufacturing of technical ceramic parts for the first time.

FreeFall Aerospace, Inc.

Academic Institution: The University of Arizona

FreeFall Aerospace develops low-cost antennas for ground and space. The company’s flexible designs have dramatically lower maintenance needs, saving industry and the government time and money on sustainment operations.

L5vel Inc.

Academic Institution: Texas A&M University

L5vel is developing autonomy for all-terrain logistics. Its product, L5vel Prime, automates all-terrain forklifts.

MicroAvionics

Academic Institution: Harvard University

MicroAvionics is developing innovative levitation technology to enable flight in the mesosphere (50-100 km altitudes). The technology uses sunlight to generate thrust, eliminating the need for onboard fuel or power, offering a sustainable method to carry near-space payloads in a region that is inaccessible to conventional aircraft and satellites.

Mithril Technologies, Inc.

Academic Institution: Massachusetts Institute of Technology (MIT)

Mithril Technologies, Inc. is developing and commercializing a new type of space-based mesh reflector antenna using a unique electrostatic actuation technology invented at MIT to enable active beam focusing, shaping and steering. This active control allows flexibility in GEO satellite communications & jamming, signal intelligence, and space-based weather monitoring, with lighter & simpler structures than phased arrays.

ModiFly

Academic Institution: University of Texas at San Antonio

ModiFly offers an affordable drone networking solution with edge and cloud AI processing, supporting dynamic mission demands through plug-and-play modules.

Pi-Radio

Academic Institution: New York University

Pi-Radio builds software-defined radios (SDRs) that enable wireless systems prototypes for communications, sensing, and electronic warfare to be built quickly and affordably. Pi-Radio has been funded by the National Science Foundation (NSF) and Defense Advanced Research Projects Agency (DARPA) SBIR/STTR programs.

Refined Imaging LLC.

Academic Institution: Louisiana State University

Refined Imaging applies new X-ray and neutron imaging technology, along with key collaborators, to develop the secure supply chain.

SoloPulse Corp.

Academic Institution: Georgia Tech

SoloPulse unlocks sensing infrastructure without the need for new hardware. With the rise of autonomy, advanced threats, and the need for more intelligible data, SoloPulse offers the necessary solutions for fast, cost-effective, high-fidelity data from any existing sensor. By introducing the capability to see from any sensor, SoloPulse is changing how the world sees.

Spectrum Defense Systems

Academic Institutions: Purdue University and Ohio Northern University

Spectrum Defense Systems is a DoD-focused startup focused on providing electronic warfare decoy capabilities to the U.S Army. Its flagship product is the Dynamic Radio Emulator System (DRES).

About National Security Innovation Network

NSIN is a program office in the U.S. Department of Defense, nested within the Defense Innovation Unit (DIU). We are set up to collaborate with a wide variety of innovators to include universities, researchers, students, entrepreneurs and start-ups. We create opportunities for collaboration across communities and connect those that might not traditionally work in national security. Together, we help drive national security innovation and develop technologies that directly support the individuals responsible for protecting our country.

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Ready for lift-off, the novel inflatable antenna system developed by FreeFall Aerospace is validated and ready for space! In partnership with the University of Arizona (UA), FreeFall successfully conducted extensive pre-flight tests, the last step before flying in space. These tests validate operation and performance in a simulated space environment from launch through the entire mission lifetime. Our Inflatable Antenna System has now been integrated for flight on the CatSat spacecraft and will ultimately provide Big Data from Small Spacecraft for a wide variety of missions.

Inflatable Cubesat Antenna

This novel inflatable antenna system developed by Tucson technology company FreeFall Aerospace, in conjunction with the University of Arizona, is a critical component of CatSat, one of eight research satellites to be launched aboard a Firefly launch vehicle now set for no earlier than January 2023. The satellites selected under NASA’s CubeSat Launch Initiative will perform technology demonstrations, conduct scientific investigations, and provide educational benefits.

 

The FreeFall Aerospace Inflatable Antenna System components include a lightweight Mylar balloon reflector, a deployment and inflation system, and small gas cartridges.

TVAC Test: FreeFall Aerospace Inflatable Antenna System

Science / Technology Question:

How can low power, high data rate communications be achieved with a Small Satellite?

Demonstrate a deployable, high-gain antenna by relaying high-definition images from orbit in near real-time.

CatSat Mission Requirements:

 

The FreeFall Aerospace antenna system utilizes an ultra-lightweight inflatable structure that can be stowed in a very small volume. Once deployed in orbit, it provides an extremely lightweight large aperture high-gain antenna. This approach will dramatically increase the total data return and overall effectiveness of Cubesats and other small satellites. The Principal Investigator of CatSat is Dr. Chris Walker, professor of Astronomy at UA and co-founder of FreeFall Aerospace. The Lead Mechanical & Systems Engineer is FreeFall’s, Aman Chandra.

 

CatSat is a 6U CubeSat built by GOMspace of Denmark that is now being integrated and tested by UA students from various departments, including Aerospace and Mechanical Engineering, Astronomy, Computer Science, and Electrical and Computer Engineering. It allows undergraduate and graduate students to get hands-on experience developing and operating a space mission and involves dozens of UA students across campus.

Once in orbit, the FreeFall antenna will deploy using compressed gas to inflate a 0.5-meter diameter Mylar spherical reflector incorporating a proprietary feed system.  Through the inflatable antenna, CatSat will transmit high-definition Earth imagery in real-time to a 6.1 m ground station antenna at Tech Parks Arizona. A second “whip” antenna will also be used to probe how Earth’s ionosphere structure varies at different times of the day. CatSat will orbit Earth approximately 15 times a day during its expected 6-month lifetime.

“Qualifying our inflatable antenna is a crucial step for FreeFall Aerospace, the University of Arizona, and Tucson’s developing space ecosystem. We’re looking forward to making this capability available for commercial, scientific, and government space missions.”

Doug Stetson, CEO of FreeFall Aerospace

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Phoenix Business Journal
By Steve Zylstra | Dec 16, 2021

FreeFall Aerospace is developing revolutionary antenna technology for ground, air, and space. Spherical antennas offer a wide field of view, efficient beam steering, and low mass to simplify and improve satellite communications. This allows entire constellations of low-cost satellites to be integrated in a complete communications network. The technology is based on research in high-frequency radio astronomy at The University of Arizona.

Read Full Article at Phoenix Business Journal:
On many clear evenings, it’s no surprise to see me casting my eyes to the stars. That’s especially true when I’m reflecting on my past while considering what lies ahead in our future.

One of the early stops in my career found me working as a principal engineer at Ford Aerospace. Even then, I knew space held the potential for paydays. Little did I realize that the commercial space industry was going to help sustain Arizona’s economy for years to come in Arizona.

There are a number of companies in the Valley and beyond that have used our state as the launch pad for ideas leading to enterprises offering products and services ranging from satellites orbiting the earth to space tourism in the next few years.

In the East Valley, the name Northrop Grumman is behind two campuses. Gilbert is home to a new administrative and engineering building created to expand the company’s Northrop Grumman’s multi-building satellite manufacturing campus, which was already one of the largest of its kind in the nation. Clients include NASA, the U.S. Department of Defense and commercial customers. A few years ago, a campus was opened in neighboring Chandler to serve as home to Northrop Grumman’s launch vehicles business.

Tempe is the home of KinetX Aerospace, the first private company qualified by NASA for deep space navigation. In addition, it offers world-class expertise flight dynamics, operations and systems engineering. The KinetX Space Navigation and Flight Dynamics team has navigated spacecraft on complex planetary exploration missions such as OSIRIS-REx, MESSENGER and New Horizons. KinetX also specializes in the design, development and operation of large-scale space systems including Iridium.

Speaking of Iridium, which has its business operations in Tempe, the company offers the only mobile voice and data satellite communications network that links people, organizations and assets to and from anywhere around the world in real time. In 2019, the company completed an upgrade of its satellite network and launched its new specialty broadband service, Iridium Certus.

Stretching to Tucson

Arizona’s commercial space corridor also stretches south to Tucson. Paragon Space Development Corporation has worked on every major human space flight program since 1999 and its hardware has flown on NASA spacecraft (e.g., Space Shuttle, International Space Station), foreign spacecraft (e.g., Soyuz, Mir) and commercial spacecraft.

Paragon’s expertise in engineering, design, analysis and manufacturing combined with its patented ECLSS Human-Rating Facility and Testing Facilities has made it a leader in the development of innovative life support and thermal control solutions. The company is part of the Northrop Grumman team that will create the Habitation and Logistics Outpost (HALO) for the Lunar Gateway outpost planned to orbit the moon.

Want to get a closer look at the moon but don’t think you’ll make the cut for NASA? World View Enterprises is the creator of the Explorer Stratospheric Capsule that will use balloons to take you and others to the stratosphere as soon as early 2024 for $50,000 each. The memorable moment will be seeing the Earth’s curvature against the blackness of space.

It’s worth noting that Paragon and World View share a common pedigree. Both companies were founded by Taber MacCallum and Jane Poynter, who have launched the company Space Perspective in Florida. The company’s Spaceship Neptune will be lifted by a SpaceBalloon for an experience similar to that being marketed by World View.

Back in Tucson, Phantom Space Corp. helps companies design, build and integrate spacecraft from single small spacecraft to the complete buildout of constellations. With a track record of successful satellite programs, spacecraft design and various space missions, one of its products is Daytona, a mass-manufactured expendable two-stage rocket considered the most efficient and cost-effective small payload rocket in the world.

FreeFall Aerospace is developing revolutionary antenna technology for ground, air, and space. Spherical antennas offer a wide field of view, efficient beam steering, and low mass to simplify and improve satellite communications. This allows entire constellations of low-cost satellites to be integrated in a complete communications network. The technology is based on research in high-frequency radio astronomy at The University of Arizona.

This overview is just a sample of what is happening in Arizona. While there are plenty of voids in space, there are far fewer when it comes to our commercial space industry.

Steve Zylstra is president and CEO of the Arizona Technology Council.

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