A six-satellite constellation engineered at Pixxel Space to deliver global coverage every 24 hours, with Hyper-spectral Data.
Roles: Structural & Mechanisms Engineer.
Technologies Used: CAD, Analysis, Microcontroller, Prototyping, GD&T, Python & Vibration Testing.
SpaceX Falcon 9 deploying Fireflies into space!
"Space is the most affordable way on Earth to collect high-resolution data, everyday."
Best Part of the Journey
⚠️ Six months before launch, we faced a tough reality—SpaceX required a primary structural frequency above 40 Hz. After design changes, ours had dropped to just 20 Hz.
🤼♂️ For two months, two teammates and I in the structural engineering team lived in the office, rebuilding components and chasing every hertz. Late nights, countless iterations, and creative hacks defined our engineering marathon.
〰 Little changed as we went on to reduce the mass and increase the stiffness of every single component on the satellite.
🎉 The breakthrough came when we redesigned the adapter between the satellite 🛰️ and the separation system on the rocket casing 🚀, boosting our frequency to 84.61 Hz, over 4x the original. We didn’t just meet SpaceX’s target—we made the satellite stronger.
Overall, Contributing to the Constellation:
After three successful technical demonstration missions, I worked on the next set of 6 satellites known as "Fireflies." This involvement allowed me to contribute to the development of the constellation that Pixxel is tirelessly building.
Guides: Tejaswi Hareesh (Vice President of Mechanical Engineering at Pixxel Space), Hari Prasad (Systems Engineer for the Firefly Mission) & Chiranjeevi R (Structural Engineering Lead).
As a Structural & Mechanisms Engineer
Designed and integrated mechanical systems for 10+ components across 6 Hyperspectral Satellites, meeting SpaceX and PSLV launch load requirements through cross-subsystem collaboration.
Performed FEM analyses to ensure vibration load compliance with 3x stiffness enhancement; correlated vibration test results with a 2% deviation.
Improved production efficiency by 25% for Pixxel's Firefly satellite via Mechanical Drawings, QA/QC standards, and team management.
Achieved 94% quality compliance for 300+ line items across 6 satellites; boosted production efficiency by 30% through partnerships with 10+ manufacturers specializing in CNC, Additive Manufacturing, and coatings.
"Wore multiple hats everyday across engineering teams to supply chain"
Detailed Spectral Data: Captures narrow, contiguous bands for precise analysis.
Material Identification: Accurately classifies materials via spectral signatures.
Environmental Monitoring: Tracks changes in vegetation health and water quality.
Agricultural Insights: Detects crop diseases and stress early.
Forestry & Land Use: Assesses forest health, tree species, and land use.
SpaceX Falcon 9 deploying Fireflies into space!
Reflection
Working on a satellite constellation was a transformative experience. I joined the team as the 20th member, and by the end, we had grown to over 300 people. I witnessed the startup journey from the seed stage to Series C.
No one on the team knew how to build one when we started three years ago. By the end, everyone had learned how to build one, and we made history by creating 'India's First Private Satellite Constellation.'
Fireflies will always be in my heart ❤️, as we built it to serve as a health monitor for planet Earth.
Currently, they are in space, beaming climate data 🌎 every day, which makes me immensely happy.
Research Publications
MEMS-based solar panel deployment for a spacecraft. (IAC Baku 2023)
Reusability of Re-entry Capsules using Shape Memory Alloys. (IAC Baku 2023)
Nuclear-powered air-breathing electric thruster propulsion system developed for space exploration vehicles. (IAC Paris 2022)
3D welding additive manufacturing humanoid for spacecraft. (IAC Paris 2022)