The honeycomb sandwich structures are extensively utilized in the satellite load bearing structure due to their superior mechanical properties. Investigating such structures and establishing their failure map implies the estimation of their equivalent elastic parameters as well as the experimental measurements of their ultimate strengths. Through a comprehensive study, this article discusses thoroughly the mechanical behavior of an aluminum honeycomb structure exposed to flat-wise compressive and flexural testing. Furthermore, an equivalent finite element model, based upon the sandwich theory, is proposed for simulating the elastic behavior of the flexural testing and comparing computational and experimental results. The comparison of results confirms accurately the usage of the sandwich theory and its related shell-volume-shell approach in the efficient modeling of honeycomb sandwich structures. In addition, the aforementioned honeycomb structure is parameterized from the geometry and material perspective. The outcome of such study reveals that the honeycomb core thickness has the greatest influence on the maximum displacement value. In addition, aluminum alloys are optimum choice for facing sheets material of the honeycomb structure.

The satellite structural mass is considered a crucial parameter during the process of satellite structural design. Sandwich structures acquire a considerable role in minimizing such mass while maintaining structural integrity. This article discusses the structural configuration, design, and analysis of a small satellite. A small Earth remote sensing satellite is chosen from the published data as a case study. Its structural design configuration is of a rectangular box that is based upon metallic alloys. Through a comprehensive study, the most suitable design configuration for the given mission is selected. A contribution has been made in developing a novel hexagonal primary structure that is based upon Aluminum honeycomb sandwich panels. The satellite configuration process and structural design procedure are thoroughly presented. The finite element modeling of honeycomb sandwich panels according to sandwich theory is introduced. Such modeling is validated numerically in comparison with published data. The analysis process is implemented using finite element analysis considering the loads during the ground and launch phases. The proposed structural design results in a significant mass reduction of 15% when compared with the baseline case study.