Students Develop 3D-Printed Camera Mount for Danish Satellite Launch

Two students from the University of Southern Denmark have designed a 3D-printed camera mount for a satellite as part of the Danish Student CubeSat Program (DISCO). The project was supported by the Danish Technological Institute (DTI), which handled the production of the component and ensured the precision required for space deployment. The satellite launch is scheduled for summer 2025.

The DISCO program gives Danish students the opportunity to design, build, and launch their own small satellites—so-called CubeSats—into space. The team, consisting of Thomas Buris Larsen and Sigrid Samsing, chose an additively manufactured aluminum solution to meet strict weight requirements.

“Objects sent into space should weigh as little as possible. In this case, we wanted to reduce the weight below a set target, which imposes significant demands on design, material, and manufacturing method. With these requirements in mind, 3D printing was the obvious choice”, said Thomas Buris Larsen, University of Southern Denmark.

To further reduce weight, the mount was designed using topology optimization—a process that removes all non-load-bearing material, leaving only the structurally essential areas. The component then underwent extensive simulations and vibration tests to ensure it could withstand the forces experienced during rocket launch.

“Before the bracket was produced, we conducted various simulations to get an idea of how the bracket would react. After production, we performed comprehensive vibration tests to ensure that the part could withstand the forces it would experience during launch”, says Thomas Buris Larsen.

“I am incredibly pleased with our collaboration with the Danish Technological Institute. Additive manufacturing has become a standard technique here on Earth, and now we are working to make it a standard technique in space as well”, says Christoffer Karoff, associate professor at the Department of Geoscience at Aarhus University and leader of DISCO.

For the Danish Technological Institute, the project demonstrates the capabilities of additive manufacturing in demanding industries.

“This project is a fantastic opportunity for us to demonstrate how the Danish Technological Institute can help Danes enter the aerospace industry. With a subject clearly designed for 3D printing and optimized with strength-calculated topology, we want to showcase a small selection of the many advantages that 3D printing can offer”, said Andreas Aakjær Andersen, Danish Technological Institute.