Impact of Thermal Contact Conductance on a 1U Cubesat Model

Abstract

Thermal control is one of the main challenges in CubeSats due to their reduced volume, high subsystem integration, and limited heat-rejection capability in the Low Earth Orbit (LEO) environment. In this class of satellites, conduction is usually the dominant mechanism for internal heat distribution, making thermal contact conductance relevant. However, its values are often still uncertain. This uncertainty arises because heat transfer through contact depends on assembly and interface conditions, such as contact pressure, surface roughness, and contamination, as well as the properties of the materials in contact. As a result, contact conductance can vary over orders of magnitude and introduce significant differences in temperature predictions and thermal margins during conceptual design. This work evaluates, through a parametric study, the impact of varying thermal contact conductance in a conceptual 1U CubeSat thermal model implemented in Thermal Desktop. The analysis considers contrasting orbital conditions and examines how contact conductance affects the thermal distribution and temperature extremes, with emphasis on internal components and the system’s main conductive paths. The results reinforce the need for contact-conductance sensitivity analyses to support thermal design decisions and reduce risks associated with these thermal predictions.