EM Solutions, a satcom systems developer, partnered with ACS Australia to design and manufacture a new satcom system, the King Cobra, for naval vessels. The system’s identical azimuth arms, typically made of machined aluminum, were a major challenge due to their weight, complexity, and corrosion concerns. To overcome these issues, ACS Australia designed and manufactured a single-piece, 1.5 x 0.5 x 0.5 meters carbon fiber/epoxy composite arm that is 65% lighter than its metallic counterpart. The arm has fewer components, requiring fewer fasteners and fittings, making it easier to install and maintain. The design meets high blast requirements and has undergone finite element analysis and physical testing to ensure its structural integrity. The composite arm also offers improved durability, corrosion resistance, and reduced power consumption. The design has won a Composites Australia Innovation Award and is now successfully integrated into the King Cobra satcom product, operating on navy vessels in Australia and Europe. The weight savings have made it possible for one person to handle the arm, a significant improvement over traditional designs.
A lightweight, modular design of carbon fiber reduces the complexity of satellite arm installation by streamlining the process for naval vessel integration.
