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Industrialising space testing: Beyond Gravity makes satellite mechanism validation scalable
To enable the serial production of a new satellite mechanism, Beyond Gravity must eliminate a critical bottleneck: its test infrastructure. Together with Zühlke, the company is developing a scalable test platform that automates thermal vacuum testing and enables the parallel validation of up to 12 mechanisms. The result: increased testing capacity, more stable processes, and production scalability.
Project at a glance:
Satellites consist of highly specialised components that must operate reliably under extreme conditions. Before being sent into space, these systems are tested under realistic conditions, such as in vacuum chambers with significant temperature fluctuations.
To enable the serial production of a new satellite mechanism, Beyond Gravity is fundamentally modernising its existing test infrastructure.
Together with Zühlke, the company is developing a new generation of automated test systems. A historically evolved testing environment is being transformed into a scalable validation platform capable of testing multiple mechanisms simultaneously.
As space production grows, testing must scale too
Among other products, Beyond Gravity develops so-called Solar Array Drive Mechanisms (SADMs). These mechanisms connect the solar panels to the satellite body, orient the panels towards the sun, and, simultaneously, transfer electrical power and signals between the satellite and the solar array.
Before these mechanisms can be deployed, they must undergo extensive testing. One of the most important procedures is the thermal vacuum test. This test simulates the space environment by creating temperature cycles and vacuum conditions. It provides critical data on the performance and reliability of the mechanisms.
In the past, Beyond Gravity produced these mechanisms in relatively small quantities and tested them individually or in small batches. With the introduction of a new product and a strategic focus on serial production, however, the requirements have changed significantly. Instead of testing individual components, the company plans to test up to twelve mechanisms simultaneously in the future.
The existing test automation system was not designed for this purpose, making maintenance and expansion increasingly difficult. As a result, the test infrastructure has become a critical bottleneck for the planned production scale-up.
“Zühlke’s team was highly professional and demonstrated a strong commitment throughout. We always felt that they genuinely cared about the project and its success.”
From an evolved test environment to an industrial platform
To address this challenge, Beyond Gravity and Zühlke launched a project to develop a new test automation solution. At the outset, both teams analysed the existing environment and jointly defined the requirements for a future system.
It quickly became clear that the project involved more than simply modernising the existing software. The entire testing system needed to be rethought. In addition to the software architecture, key components of the test hardware would also need to be redesigned or replaced.
The objective was to create a robust, modular platform capable of reliably controlling complex test procedures while supporting significantly higher testing volumes.
A modular architecture for complex test campaigns
At the heart of the new system is a central control unit known as the “Test Master”. This component coordinates the entire testing process, from configuration and execution of test sequences through to monitoring and fault handling.
Several specialised modules perform different tasks within the system. For example, they control the temperature and pressure conditions inside the vacuum chamber, manage the mechanics of the test objects, collect measurement data, and carry out automated analyses. This modular architecture enables test engineers to configure complex test profiles flexibly while ensuring reliable and repeatable execution.
The test system is also being comprehensively modernised at the hardware level. Measuring how instruments, power supplies, and motor controllers are being upgraded and integrated into the new system architecture. The result is a tightly integrated software and hardware platform that automates and continuously monitors the entire testing process.
A future-proof foundation for serial production
With the new test automation platform, Beyond Gravity now has a scalable infrastructure for validating its satellite mechanisms.
The solution enables multiple mechanisms to be tested in parallel, significantly increasing testing capacity. At the same time, the modular architecture improves maintainability and reduces dependence on legacy technologies.
Most importantly, the platform removes a key bottleneck in the production process. Only through the new test infrastructure is it possible to implement the planned serial production of the mechanism.
As Thierry Bouquet, Manager Test Engineering at Beyond Gravity, explains: “Today we have a professional solution where previously we had a fragmented testing environment. This development enables our team to make a decisive contribution to one of our company’s strategic objectives: the serial production of this mechanism.”
Laying the foundation for the next generation of space manufacturing
The new test automation system forms part of a broader transformation at Beyond Gravity. In parallel with the project, a new cleanroom and production environment is being established to enable the industrial manufacturing of the mechanisms.
Together with Zühlke, Beyond Gravity has transformed a historically evolved testing environment into a future-ready validation platform.
The company now has the technical foundation required to test complex space components efficiently, reliably, and at industrial scale.
