Project Stratosphere: Sustainable CubeSat Design & Simulation
Learn how students at Gower College Swansea designed a low-cost 1U CubeSat for ozone layer monitoring and atmospheric research in the UK stratosphere.
EESW STEM CYMRU · GOWER COLLEGE SWANSEA
PROJECT
STRATOSPHERE
Design & Simulation of a Sustainable CubeSat for Ozone Layer and Atmospheric Monitoring
MISSION TYPE
Environmental Monitoring
ALTITUDE TARGET
10–20 km
FORMAT
1U CubeSat (10×10×10cm)
Lewis Whitefoot · Mahiba Hossain · Miles Li · Oleksandra Roshchupkina · Rayan Haque · Oliwier Lesiak
In association with University of South Wales · 2025–2026
MISSION OVERVIEW
EXECUTIVE
SUMMARY
Gower College Swansea, in association with the University of South Wales, designed and simulated a 1U CubeSat payload targeting ozone layer and atmospheric greenhouse gas research above Wales.
MISSION
Environmental Monitoring — Ozone & UV Research
BUDGET
£88.30 of £200 limit — 56% savings achieved
ALTITUDE
10–20 km via High-Altitude Balloon (B2Space)
SENSOR SUITE
Ozone · UV · Pressure · Temp/Humidity · GPS
PROJECT STRATOSPHERE · GOWER COLLEGE SWANSEA · 2025–2026
MISSION TEAM · GOWER COLLEGE SWANSEA
THE TEAM
Six A-Level students | In association with University of South Wales
OR
Oleksandra Roshchupkina
TEAM LEADER
Physics, Maths, Further Maths
Coordinates tasks, manages communication and project scheduling.
MH
Mahiba Hossain
SENSORS & PAYLOAD ENG.
Chemistry, Physics, Maths
Researches sensor technology and atmospheric measurement principles.
RH
Rayan Haque
ELECTRONICS & CODING ENG.
Electronics, Maths, Physics
Designs circuits, writes Arduino code, tests systems.
LW
Lewis Whitefoot
STRUCTURE & DESIGN ENG.
Chemistry, Physics, Maths
CAD modelling, materials selection, structural design.
ML
Miles Li
SUSTAINABILITY & RISK MGR
Chemistry, Physics, CS
Risk assessment, sustainability compliance, environmental impact.
OL
Oliwier Lesiak
SYSTEMS & PAYLOAD ENG.
Physics, Electronics, Maths
Tinkercad simulations, electronic design, systems integration.
Contact Teacher: Victoria James · Company Engineer: Leshan Uggalla
PROJECT STRATOSPHERE · GOWER COLLEGE SWANSEA · 2025–2026
MISSION DEFINITION · SECTION 3
MISSION
DEFINITION
To design, simulate, and plan a low-cost high-altitude CubeSat payload for ozone layer and greenhouse gas research above Wales.
CORE OBJECTIVES
Design integrated environmental sensing payload within £200
Select ozone, UV, temperature and pressure sensors
Simulate electronics using Tinkercad software
Calculate power budget for −50°C operation
Design thermally insulated 1U CubeSat structure
Conduct risk assessment and feasibility study
FUNCTIONAL REQUIREMENTS
Ozone/UV/Temp/Pressure sensors · Data timestamps · Altitude reference
ENVIRONMENTAL REQUIREMENTS
−50°C tolerance · Low-pressure resilience · Full structural insulation
DATA & COMMUNICATION
SD card onboard storage · LoRa theoretical plan · UK CAA compliance
ALTITUDE: 10–20 km
FORMAT: 1U CubeSat
TEMP: −40°C to −50°C
BUDGET: £200 max
SYSTEM DESIGN · SECTION 4
STRUCTURAL
DESIGN
10×10×10 cm 1U CubeSat format. Aluminium alloy (6061-T6) frame with 3D-printed internal chassis modelled in TinkerCAD.
COMPONENT
SPEC
COST
Seeeduino Lotus Cortex-M0+
ATSAMD21, 12 Grove ports
£7.97
LiPo Battery
3.7V, 2Ah, cold-rated
£22.10
Ozone Sensor (DFRobot)
0–10ppm, 10ppb res.
£43.08
GPS Module (Air530)
50,000m altitude mode
£11.77
Pressure Sensor (SPA06)
Barometric altitude calc.
£0.00
Temp/Humidity (AHT20)
−40°C industrial grade
£3.38
£88.30 / £200
EPP foam + Mylar blanket + Kapton tape
Chemical heat packs on battery & GPS
PROJECT STRATOSPHERE · 2025–2026
ELECTRICAL ENGINEERING · SECTION 4.2
ELECTRONICS &
SENSOR SUITE
Grove-compatible plug-and-play sensor integration via Seeeduino Lotus Cortex-M0+
O₃
OZONE SENSOR
DFRobot Gravity IIC
Range: 0–10 ppm
Resolution: 10 ppb
Interface: I²C
Cost: £43.08
Electrochemical detection principle
PRIMARY MISSION SENSOR
GPS
GPS MODULE (Air530)
Grove — GPS Air530
Max Altitude: 50,000 m (no COCOM limit)
Interface: UART/Grove
Cost: £11.77
Real-time coordinate tracking
RECOVERY TRACKING
P
AIR PRESSURE SENSOR
Grove Barometer SPA06-003
Barometric altitude calculation
Uses Barometric Formula: P = P₀·e^(-kTmgh)
Interface: I²C/Grove
Cost: Included in kit
ALTITUDE REFERENCE
T°
TEMP & HUMIDITY
Grove AHT20 — Industrial Grade
Operating range: −40°C to +85°C
Monitors internal heat pack efficiency
Interface: I²C/Grove
Cost: £3.38
THERMAL MONITORING
PROJECT STRATOSPHERE · 2025–2026
ATMOSPHERIC PHYSICS · SECTION 4.4
ATMOSPHERIC
SCIENCE
Vertical ozone concentration profile over Wales. Barometric Formula correlates live pressure sensor readings with altitude in real-time.
OZONE LAYER PROFILE
Target altitude: 15–35 km
Expected O₃: 2–8 ppm
Sensor range: 0–10 ppm ✓
Peak concentration: ~25 km
STRATOSPHERIC CONDITIONS
Temperature: −40°C to −50°C
Pressure: ~1% of sea-level
Air density: ~1% of sea-level
Wind: High velocity — stability critical
BAROMETRIC FORMULA
Arduino calculates altitude from live barometric pressure readings against known sea-level baseline at Gower College.
PROJECT STRATOSPHERE · GOWER COLLEGE SWANSEA · 2025–2026
THERMODYNAMICS & POWER · SECTION 4.1 & 4.2
Dual-strategy thermal protection to maintain electronics above 0°C at −50°C external temperature.
THERMAL THREATS
LiPo Battery
Internal resistance spikes below 0°C — risk of mid-flight shutdown
Microcontroller
Potential freeze below −30°C operating threshold
GPS Module
Signal loss if temperature drops below −20°C
Condensation
Dew point risk on PCBs during ascent through clouds
PROTECTION STRATEGY
EPP FOAM INSULATION
Low thermal conductivity. Acts as conduction barrier between electronics and exterior.
MYLAR THERMAL BLANKET
Reflects infrared radiation back inward. Aerospace industry standard (NASA approved).
CHEMICAL HEAT PACKS
Exothermic reaction (4Fe + 3O₂ → 2Fe₂O₃ + heat). 5–8 hrs of active warmth for battery & GPS.
KAPTON TAPE
Stays adhesive −269°C to +400°C. Aerospace standard fastening.
SILICA GEL DESICCANTS
Absorbs moisture. Prevents PCB short circuits from condensation.
POWER BUDGET
LiPo 3.7V / 2Ah = 7.4 Wh total capacity
ESTIMATED RUNTIME
~5.9 hours continuous
Exceeds target flight duration of 1.5–3 hours
PROJECT STRATOSPHERE · 2025–2026
RISK ASSESSMENT · SECTION 4.7
RISK ASSESSMENT
Five identified key risks rated by Likelihood × Impact. All risks have mitigation strategies in place.
01 · HIGH-SPEED IMPACT
LIKELIHOOD: MEDIUM
IMPACT: HIGH
Balloon burst causes uncontrolled payload descent at dangerous speed.
Parachute deployment + EPP foam crumple zone to absorb impact energy.
ESTIMATED MITIGATION COST: £25–£45
02 · AVIATION COLLISION
LIKELIHOOD: LOW
IMPACT: CRITICAL
Balloon entering controlled airspace risks collision with aircraft.
NOTAM filed with CAA. Radar reflector attached. CAA CAP 673 compliant.
COST: £15 (reflector) + £0 NOTAM
03 · BATTERY COLD FAILURE
LIKELIHOOD: HIGH
IMPACT: HIGH
LiPo batteries fail at −50°C, cutting power to all systems mid-flight.
EPP foam + Mylar insulation + chemical hand warmers taped to battery.
COST: £5–£10
04 · ENVIRONMENTAL POLLUTION
LIKELIHOOD: LOW
IMPACT: MEDIUM
GPS tracker failure leaves CubeSat as unrecovered environmental litter.
Dual redundant tracking: LoRa radio + GSM/cellular backup systems.
COST: £70–£120
05 · PCB MOISTURE DAMAGE
LIKELIHOOD: MEDIUM
IMPACT: HIGH
Cloud penetration and dew point condensation causing PCB short circuits.
Conformal coating spray on all PCBs + silica gel desiccant packs inside.
COST: £10–£20
PROJECT STRATOSPHERE · 2025–2026
BUDGET PLANNING · SECTION 5
BUDGET
BREAKDOWN
£88.30 SPENT
£200 LIMIT
£111.70 REMAINING — 56% BUDGET SAVED
COMPONENT
UNIT PRICE
STATUS
Ozone Sensor (DFRobot)
£43.08
CRITICAL
LiPo Battery (RS PRO)
£22.10
POWER
GPS Module (Air530)
£11.77
NAVIGATION
Seeeduino Lotus Board
£7.97
COMPUTE
AHT20 Temp/Humidity
£3.38
SENSOR
Barometer SPA06-003
£0.00
SENSOR
TOTAL
£88.30
ON BUDGET
*Excludes insulation materials (EPP, Mylar, Kapton, heat packs) est. £15–£30
FINAL ESTIMATE: ~£103–£120 all-in (well within £200)
CONCLUSION & EVALUATION · SECTION 7–9
CONCLUSIONS
PROJECT SUCCESS ✓
The 1U CubeSat design meets all functional, environmental, and budget requirements. Grove plug-and-play system eliminates high-altitude soldering failure risk.
SCIENTIFIC VALUE
Vertical ozone profile data (2–8 ppm at 15–35 km) will contribute to greenhouse gas impact research over Wales. High academic and environmental relevance.
FUTURE RECOMMENDATIONS
Integrate LoRa real-time telemetry module
Add CO₂/CH₄ gas sensors
High-definition camera for visual verification
Custom 3D-printed internal chassis for mass reduction
PROJECT STRATOSPHERE · GOWER COLLEGE SWANSEA · 2025–2026 · EESW STEM CYMRU
- cubesat
- stem-project
- environmental-monitoring
- ozone-layer
- aerospace-engineering
- high-altitude-balloon
- satellite-design