After AST SpaceMobile developed a satellite technology that provided internet connectivity to cell phones, they approached AT&T to collaborate with them and create a space-based cellular broadband network. Their next step was finding containers large enough to ship the communication satellites from the manufacturing facility to their launch site. The containers had to offer ample protection to prevent damage during transport, but also be small enough to fit into their intended tractor trailers. Much like Goldilocks and the three bears, Custom Case Group delivered a strategically customized transport solution that was “just right.”
A representative from AST contacted Custom Case Group to provide a quote for the company’s prototype satellite. They required shock mount protection for the new satellites, but they needed to be contained in the smallest envelope possible to fit up to five containers into a 53’ semi refer trailer.
Compared to other potential manufacturers, Custom Case Group presented the best option – combining reinforced engineering with high-quality material construction to guarantee maximum safety and security during transport.
Several of AST’s team were in different locations around the world. During the customization process, Custom Case Group conducted weekly engineering meetings with the case manufacture and AST to keep everyone up to speed on the progress of the project and discuss any challenges they encountered during the initial manufacturing process.
The main structure of the container included a base, base plate, wire rope isolators and a two-part lid. Several features were added for improved safety during intra-facility transfer and external transport: forklift tubes for floor movements, lifting points to accommodate crane lift operations, and load-proof attachment points for restraint during transportation. The shipping containers also accommodated for removable casters.
The lid sections were completely removable and were able to be placed and detached without using a crane. Each lid had an inlet port to accommodate an external heating and cooling unit to maintain a steady temperature within the container during storage and transport.
In addition to being waterproof to rain, hail or snow, the insulated shipping container included several other safety features to prevent transport damage or contamination upon delivery:
- Electrostatic discharge isolation during transport
- Shock sensors, vibration registers and temperature/humidity sensors were mounted to the baseplate
- Silica gel basket with a relief valve to provide pressure relief for low-pressure traveling conditions
- Mechanisms were compliant with ISO9 clean environments
Custom Case Group’s proven success with the initial five shipping containers is poised to help AST and AT&T ship subsequent satellites with “out-of-this-world” protection from shock, vibration, moisture and impact.
