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Communications Satellite Product

Overview

A communications satellite is a relay platform parked in geostationary orbit, where its 24-hour period matches Earth's rotation so it appears fixed over one longitude and ground antennas never have to track it. The spacecraft splits cleanly into a service bus and a payload. The bus keeps the satellite alive and pointed; the payload does the paid work of receiving weak uplink signals, shifting them in frequency, amplifying them by ten orders of magnitude and beaming them back down.

The structure is built around a Spacecraft Structure central thrust tube that carries launch loads into a ring of honeycomb sandwich panels, which double as equipment radiators. Bolted to those panels is the Communications Payload: a bent-pipe repeater whose receive reflectors, low-noise amplifiers, frequency converters and high-power amplifiers form the signal chain. Power comes from the Electrical Power Subsystem subsystem, with two sun-tracking solar wings and a Li-ion battery to ride through eclipse. The Attitude Control Subsystem holds the antennas pointed at their coverage region, and the Propulsion Subsystem subsystem raises the orbit after launch and trims the station for fifteen years.

How it works

After separation the satellite is in a transfer orbit and must climb to GEO. The liquid apogee engine in the propulsion subsystem fires at successive apogees to circularize the orbit, after which xenon ion thrusters take over the small, relentless north-south corrections that fight luni-solar perturbation. Once on station, the solar wings deploy and the solar array drive mechanisms rotate them to face the Sun continuously, feeding the power conditioning unit that regulates the bus and charges the battery.

The repeater runs continuously. Each transmit reflector is illuminated by a feed horn, and the receive chain hands signals through low-noise amplifiers and converters before the Command & Data Handling computer-managed amplifiers and channel filters drive them out again. Across all of it, the Thermal Control Subsystem control subsystem dumps amplifier waste heat through radiators and heat pipes while survival heaters protect cold components, and the TT&C Subsystem link keeps operators in contact with the spacecraft.

Build & assembly graph

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Bill of materials

9 top-level lines · 110 rows shown · 725 parts total · indented to 3 levels
# Item / sub-assembly Part no. Qty/assy Ext. qty Parts Type
1 Spacecraft Structure 4 parts communications-satellite-structure 1 72 assembly
1.1 Central Thrust Tube communications-satellite-thrust-tube 1 part
1.2 Honeycomb Sandwich Panel 3 parts communications-satellite-panel 6 11 assembly
1.2.1 Aluminum Honeycomb Core communications-satellite-honeycomb-core 6 part
1.2.2 CFRP Facesheet communications-satellite-facesheet 12 part
1.2.3 Potted Panel Insert communications-satellite-panel-insert 48 part
1.3 Separation Ring communications-satellite-separation-ring 1 part
1.4 Fastener Set fastener-set 4 part
2 Communications Payload 8 parts communications-satellite-payload 1 258 assembly
2.1 Receive Antenna Reflector communications-satellite-rx-antenna 2 part
2.2 Feed Horn 3 parts communications-satellite-feed-horn 4 4 assembly
2.2.1 Corrugated Horn Flare communications-satellite-horn-flare 4 part
2.2.2 Orthomode Transducer communications-satellite-omt 4 part
2.2.3 Connector connector 8 part
2.3 Low-Noise Amplifier 3 parts communications-satellite-lna 4 4 assembly
2.3.1 Bare PCB pcb-bare 4 part
2.3.2 SMD Passive (R/C/L) smd-passives 4 part
2.3.3 Connector connector 8 part
2.4 Frequency Converter 4 parts communications-satellite-frequency-converter 4 5 assembly
2.4.1 Bare PCB pcb-bare 4 part
2.4.2 SMD Passive (R/C/L) smd-passives 4 part
2.4.3 Microcontroller mcu 4 part
2.4.4 Connector connector 8 part
2.5 Output Multiplexer (OMUX) 2 parts communications-satellite-output-multiplexer 2 13 assembly
2.5.1 Waveguide Channel Filter communications-satellite-waveguide-filter 12× 24 part
2.5.2 Combining Manifold communications-satellite-manifold 2 part
2.6 Traveling-Wave Tube Amplifier 3 parts communications-satellite-twta 24× 24 6 assembly
2.6.1 Traveling-Wave Tube communications-satellite-twt 24 part
2.6.2 Electronic Power Conditioner 3 parts + deeper › communications-satellite-epc 24 3 assembly
2.6.3 Connector connector 48 part
2.7 Solid-State Power Amplifier 3 parts communications-satellite-sspa 8 4 assembly
2.7.1 Bare PCB pcb-bare 8 part
2.7.2 SMD Passive (R/C/L) smd-passives 8 part
2.7.3 Connector connector 16 part
2.8 Transmit Antenna Reflector communications-satellite-tx-reflector 2 part
3 Electrical Power Subsystem 4 parts communications-satellite-power 1 101 assembly
3.1 Solar Array Wing 3 parts communications-satellite-solar-wing 2 8 assembly
3.1.1 Solar Cell Panel communications-satellite-solar-panel 8 part
3.1.2 Deployment Hinge communications-satellite-deployment-hinge 6 part
3.1.3 Wire Bundle wire-bundle 2 part
3.2 Solar Array Drive Mechanism 3 parts communications-satellite-sadm 2 23 assembly
3.2.1 Stator Assembly 3 parts + deeper › stator-assembly 2 3 assembly
3.2.2 Rotor Assembly 4 parts + deeper › rotor-assembly 2 19 assembly
3.2.3 Slip Ring Assembly communications-satellite-slip-ring 2 part
3.3 Li-ion Battery 2 parts communications-satellite-battery 1 33 assembly
3.3.1 LiPo Cell lipo-cell 32× 32 part
3.3.2 BMS Board bms-board 1 part
3.4 Power Conditioning Unit 4 parts communications-satellite-pcu 1 6 assembly
3.4.1 Bare PCB pcb-bare 2 part
3.4.2 IGBT Power Module igbt-module 2 part
3.4.3 SMD Passive (R/C/L) smd-passives 1 part
3.4.4 Microcontroller mcu 1 part
4 Attitude Control Subsystem 5 parts communications-satellite-adcs 1 143 assembly
4.1 Reaction Wheel 4 parts communications-satellite-reaction-wheel 4 31 assembly
4.1.1 Stator Assembly 3 parts + deeper › stator-assembly 4 3 assembly
4.1.2 Rotor Assembly 4 parts + deeper › rotor-assembly 4 19 assembly
4.1.3 Neodymium Magnet neodymium-magnet 32 part
4.1.4 Flywheel Rotor communications-satellite-flywheel 4 part
4.2 Magnetorquer communications-satellite-magnetorquer 3 part
4.3 Star Tracker 3 parts communications-satellite-star-tracker 2 3 assembly
4.3.1 Optical Head communications-satellite-optical-head 2 part
4.3.2 Compute SoC Module soc-module 2 part
4.3.3 Bare PCB pcb-bare 2 part
4.4 Sun Sensor communications-satellite-sun-sensor 4 part
4.5 Inertial Measurement Unit 3 parts communications-satellite-imu 1 6 assembly
4.5.1 Fiber-Optic Gyroscope communications-satellite-gyro 4 part
4.5.2 Microcontroller mcu 1 part
4.5.3 Bare PCB pcb-bare 1 part
5 Propulsion Subsystem 6 parts communications-satellite-propulsion 1 53 assembly
5.1 Liquid Apogee Engine 2 parts communications-satellite-apogee-engine 1 5 assembly
5.1.1 Thrust Chamber & Nozzle communications-satellite-thrust-chamber 1 part
5.1.2 Propellant Valve 2 parts + deeper › communications-satellite-prop-valve 2 2 assembly
5.2 Ion Thruster 3 parts communications-satellite-ion-thruster 4 7 assembly
5.2.1 Discharge Chamber communications-satellite-discharge-chamber 4 part
5.2.2 Accelerator Grid Assembly communications-satellite-grid-assembly 4 part
5.2.3 Power Processing Unit 3 parts + deeper › communications-satellite-ppu 4 5 assembly
5.3 Propellant Tank communications-satellite-propellant-tank 2 part
5.4 Xenon Tank communications-satellite-xenon-tank 1 part
5.5 Propellant Valve 2 parts communications-satellite-prop-valve 8 2 assembly
5.5.1 Valve Body communications-satellite-valve-body 8 part
5.5.2 O-Ring Set oring-set 8 part
5.6 Propellant Feed Lines communications-satellite-prop-line 1 part
6 Thermal Control Subsystem 4 parts communications-satellite-thermal 1 40 assembly
6.1 Radiator Panel communications-satellite-radiator 2 part
6.2 Heat Pipe communications-satellite-heat-pipe 8 part
6.3 MLI Blanket communications-satellite-mli-blanket 6 part
6.4 Survival Heater 2 parts communications-satellite-heater 12× 12 2 assembly
6.4.1 Heating Element heating-element 12 part
6.4.2 Heater Thermostat communications-satellite-thermostat 12 part
7 Command & Data Handling 2 parts communications-satellite-avionics 1 18 assembly
7.1 On-Board Computer 4 parts communications-satellite-obc 1 4 assembly
7.1.1 Compute SoC Module soc-module 1 part
7.1.2 Microcontroller mcu 1 part
7.1.3 SMD Passive (R/C/L) smd-passives 1 part
7.1.4 Bare PCB pcb-bare 1 part
7.2 Remote Interface Unit 4 parts communications-satellite-io-board 2 7 assembly
7.2.1 Microcontroller mcu 2 part
7.2.2 SMD Passive (R/C/L) smd-passives 2 part
7.2.3 Bare PCB pcb-bare 2 part
7.2.4 Connector connector 8 part
8 TT&C Subsystem 2 parts communications-satellite-ttc 1 12 assembly
8.1 TT&C Transponder 4 parts communications-satellite-ttc-transponder 2 5 assembly
8.1.1 Bare PCB pcb-bare 2 part
8.1.2 SMD Passive (R/C/L) smd-passives 2 part
8.1.3 Microcontroller mcu 2 part
8.1.4 Connector connector 4 part
8.2 Omnidirectional Antenna communications-satellite-omni-antenna 2 part
9 Spacecraft Harness 2 parts communications-satellite-harness 1 28 assembly
9.1 Wire Bundle wire-bundle 4 part
9.2 Connector connector 24× 24 part

Sourcing — likely vendors

Companies that make this · indicative price $50k–$500M · MOQ & lead are typical
VendorHQSpecialtyMOQLead time
🇺🇸SpaceX
spacex.com ↗
Hawthorne, US Launch & spacecraft made to order 52–104 wks
northropgrumman.com ↗ Falls Church, US Space & defense made to order 52–104 wks
🇫🇷Airbus
airbus.com ↗
Toulouse, FR Aerospace OEM made to order 52–104 wks
🇺🇸Rocket Lab
rocketlabusa.com ↗
Long Beach, US Launch & spacecraft made to order 52–104 wks
thalesaleniaspace.com ↗ Cannes, FR Satellites made to order 52–104 wks

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