A Rapid Fabrication Methodology for Payload Modules, Piloted for the Observation of Queen Honey Bees (Apis mellifera) in Microgravity

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Payload performance tests_ Category headings are bolded_

Payload performance testing
Test Name	Aim	Process	Min. Duration	Outcome	Output
Mechanical
Static load	Ensure payload can withstand static load.	≥15 lb of static load applied to each axis of the chassis (x, y, z) for 2 min	2 min, per axis	Each axis was photographed before/during/after weight application; no deformation or destruction of the capsule is observed.	Photo
Accelerative load and shock	Ensure payload withstands flight g-loads and shock.	30 g (×2 nominal peak acceleration) applied in the form of static load force (i.e., ×30 the weight of the object) to each object.	50 ms	To incorporate the Acceleration Load and Shock tests into the Static Load test, 30 lbs of static load was tested on each axis.
Vibration	Ensure hardware can perform in a vibration environment.	Periodic vibration, 7.85 g at 50 Hz applied via Vortex Mixer (VWR, 3000 rpm/4.9 mm orbit), and a qualitative assessment of damage or displacement.	1 min, per axis	No changes (damage, shifting, debris) occur over the course of several minutes. Note: This test is not directly comparable to a random vibration environment.	Video
Thermal
Touch-temperature	Ensure payload has minimal thermal effect on neighboring experiments.	Temperature of external faces of chassis sampled by IR-camera (FLIR C3, FLIR Systems) with all heat-generating electrical systems running for 30 min.	30 min, or until temp. plateau	External temperature leveled at 26.7°C and 31.7°C, respectively, with electronic heating systems and battery run a maximum performance for 30 min (simulating an electronic “loss of control,” reaching an internal temperature of 53.3°C).	Temp. time course
Other
Flammability	Ensure non-ignitable or self-extinguishing properties.	Prolonged exposure to an open flame, simulating an electronic or battery short.	1 min	Foam held over open flame is shown to self-extinguish with minimal shape change or expansion; corroborated by technical data sheet for material.	Video
Fragmentation (Point-of-Force)	Ensure minimal particulate in case of payload fragmentation.	Weighted chisel (6 lb) dropped from 1 m onto the chassis, head-on and top-down video used to document the size and amount of particulate generated.	n/a	Foam in contact with the sharp edge broke into multiple pieces but produced minimal dust. Much of the module stayed intact, components remained in place, and the specimen compartment deflected blow without damage.	Video

Experimental module weight allotment_ Category headings are bolded; in-line bolded values represent the summed weight (g) of the components within that category (listed below the heading), followed in parenthesis by the weights’ percentage out of the of the maximum weight limit_ The total experimental module weight was 439_6 g, with 59_4 g of unallotted weight remaining_

Maiden flight 2U payload module characteristics (L = 102 mm, W = 102 mm, H = 200 mm)
Item	Bulk weight	Unit	Amount	Unit	Weight (g)
Housing components					146.6 (29%)
Foam housing (not including coating)	0.096	g/cm3	1,226	cm3	117.7
Paint coating					16.0
Silicon straps	6.45	g	2	pcs	12.9
Electronic and video components					211.4 (42%)
GoPro Hero5 Session	72.3	g	1	Pcs	72.3
Lens	40.6	g	1	pcs	40.6
Battery	37.0	g	1	pcs	37.0
Wires	20.0	g	1	pcs	15.0
USB connector	12.0	g	1	pcs	12.0
Lens assembly	10.0	g	1	pcs	10.0
NeoPixel Ring LED light	6.2	g	1	pcs	6.2
Custom connector board	6.0	g	1	pcs	6.0
Feather Adalogger	5.5	g	1	pcs	5.5
Heating pad	3.8	g	1	pcs	3.8
Sensors board (temp and humidity)	3.0	g	1	pcs	3.0
Bee compartment					81.6 (16%)
Acrylic compartment (including lid)	1.185	g/cm3	50	cm3	59.3
Beeswax	20.0	gr	1	pcs	20.0
Worker bees	0.113	gr	10	pcs	1.1
Queen bee	0.193	gr	1	pcs	0.2
Solid sugar fondant	1.0	gr	1	pcs	1.0
Total weight					439.6 (88%)
Max. weight					499.0