How T4i Accelerated Their Engineering Workflow 10x For An Optimized Pressurized Tank
From Earth observation to communications and scientific research, small satellites and constellations are enabling new business models, faster deployment cycles, and greater mission flexibility. This shift is pushing aerospace companies to rethink how space systems are designed, built, and launched.
At the heart of this transformation lies propulsion: a core enabler of mobility, maneuverability, and mission longevity in orbit. For new propulsion system providers like T4i, the challenge is to deliver compact, high-performance solutions that fit within the extreme size, weight, and cost constraints of CubeSats and small satellites. Every component must be optimized for multifunctionality, structural integrity, and manufacturability, often in a fraction of the time allowed by traditional aerospace development cycles.
This case study explores how T4i leveraged Cognitive Design to divide by 10 the development cycle of a pressurized aluminum tank designed to operate within a 1U CubeSat envelope and withstand high internal pressures. By integrating structural performance objectives and additive manufacturing constraints into a single AI-driven Generative Design workflow, T4i was able to rapidly explore, evaluate, and optimize complex internal geometries. The result: a structurally robust, lightweight, and print-ready tank design, delivered in a fraction of the time typically required with traditional CAD and simulation tools.
.avif)
Results achieved
7 days
T4i saved 7 days of development time by using Cognitive Design instead of traditional CAD tools, cutting engineering lead time by 92%.
85% mechanical strength
Compared to the initial design, T4i achieved a 85% reduction of the Von Mises Stress with the most optimized lattice-shell combination.
Thanks to Cognitive Design, we were able to rapidly design and validate a structurally optimized tank that fits within our CubeSat constraints, integrates all required functions, and meets demanding pressure requirements. It’s a game-changer for enabling component design exploration for high-performance propulsion in small satellite platforms. - Nicolas Bellomo, CTO at T4i
Interested in reading the full case study?
Fill in the form below to instantly receive the full case study.
Aeronautics Challenges We Address
FAQs
Explore our frequently asked questions to understand how our software can benefit you.
T4i leveraged Cognitive Design's AI-driven generative workflow to compress the development cycle of a pressurized aluminum tank for a 1U CubeSat envelope by a factor of 10, saving 7 days of engineering time (a 92% reduction). The platform enabled rapid exploration and optimization of complex internal lattice-shell geometries while integrating additive manufacturing constraints from the first iteration.
Compared to the initial design, T4i achieved an 85% reduction in Von Mises stress using the most optimized lattice-shell combination identified through multi-objective exploration in Cognitive Design. The resulting design was structurally robust, lightweight, and print-ready, meeting demanding internal pressure requirements within the strict 1U CubeSat envelope constraints.
Cognitive Design's generative workflow includes multi-objective exploration for lattice and TPMS (Triply Periodic Minimal Surface) geometries, enabling engineers to evaluate combinations of shell and infill structures against pressure resistance, mass, and printability simultaneously. For T4i's pressurized tank, this identified the optimal lattice-shell configuration without requiring manual iteration between separate CAD and FEA tools.
New Space programs demand compact, high-performance components delivered within aggressive development timelines and tight mass and volume budgets. Cognitive Design's integrated AI-driven exploration, real-time FEA validation, and additive manufacturing constraint embedding allow engineers to evaluate dozens of configurations within a single session, directly addressing the optimization density and speed required by CubeSat and small satellite propulsion programs.
Nicolas Bellomo, CTO at T4i, stated that Cognitive Design enabled the team to rapidly design and validate a structurally optimized tank fitting within CubeSat constraints, integrating all required functions and meeting demanding pressure requirements. He described the platform as a game-changer for enabling component design exploration for high-performance propulsion in small satellite platforms.
Automotive Challenges We Address
Defense Challenges We Address
Built for the Cognitive Era of Engineering
Shorten product development cycle from the earliest concept phase.
Product engineering cycle
Product engineering cycle
Reusability of engineering workflows
Unlock Your Design Potential
Request a demo to see how Cognitive Design by CDS can revolutionize your engineering workflow