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.

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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%.
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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.

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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

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