Rapid Manufacturing of a Custom Small Satellite: The MAD-SPRINT Approach

In 2024, The Aerospace Corporation developed the concept of a Hybrid Additively Manufactured Satellite Technology Experiment (HASTE) prototype that looks to develop a ground-based platform to demonstrate Hybrid Additive Manufacturing (AM) design and analysis in 2024. Since that time, the team has continued to develop the research and embarked on a new project named Manufacturing, Analysis and Design of Satellite Payloads for Rapid Integration of Next-gen Technology (MAD-SPRINT). While similar to HASTE, the MAD-SPRINT program is focused on developing an orbital payload platform within a very short timeline, 6-8 weeks. In this paper, we will discuss the motivation of MAD-SPRINT, the updated prototype, results, and lessons learned.