This thesis presents the structural and thermal design of a CubeSat-based rover system for lunar surface exploration, developed with standard 3U CubeSat as foundation. The study focuses on the integration of a mobility platform, capable of being deployed from a lunar lander, on to the 3U CubeSat. Detailed finite element analysis (FEA) was conducted to ensure structural survivability under launch conditions, including quasi-static, random vibration, and shock loads. The first natural frequency was found to be 267 Hz, exceeding the 115 Hz threshold across major spacecraft launchers. Maximum von Mises stress reached 300 MPa under the worst-case shock loading, yielding a minimum margin of safety of 0.10. Thermal analysis using passive insulation strategies demonstrated that all subsystem components remained within -20°C to +65°C under lunar surface conditions. Mobility performance was validated through terramechanics modelling and field testing on Earth's sandy terrain, where the prototype exhibited static and dynamic sinkage within 11‰ and 9‰ of analytical predictions, respectively. These results demonstrate that with appropriate design strategies and material selection, a CubeSat-Based Rover configuration can be feasibly integrated within a 3U CubeSat. While further studies—such as radiation tolerance, dust mitigation, lunar analogue terrain testing, and structural testing—are required, the findings highlight the potential of this architecture as a standardized, low-cost platform for short-duration lunar surface missions.
Dataset: https://doi.org/10.4121/uuid:6bd1d545-e071-4f7b-a457-e213909b878f