Aluminum Solar Sail Prototype -- 2

I’m preparing a technology-demonstration flight that will use sunlight alone to push a small spacecraft toward the Moon. The immediate milestone is a functional prototype of the sail itself, built primarily from aluminum alloys rather than the more common polymer films. I already have mission parameters and envelope constraints; what’s missing is the tangible hardware that proves the concept on the ground.

You will turn my preliminary sketches and requirements into a build-ready package. This includes choosing the exact alloy and surface finish that optimise reflectivity, designing the fold/roll deployment mechanism, and making sure the membrane stays flat and survives launch loads. I expect a complete digital model, stress and thermal analyses, and clear fabrication drawings that a machine shop can follow without additional interpretation.

Deliverables
• Solid-model CAD of the full sail, booms, and hub
• FEA and thermal reports showing margins for launch, deployment, and sustained illumination
• Manufacturing drawings with tolerances and material call-outs for every part
• Step-by-step assembly and packing procedure aligned with a CubeSat-class bus

Acceptance criteria: the stowed package must fit within a 1U volume, total mass under 400 g, deployed area at least 20 m², and factor-of-safety ≥1.25 on all load cases supplied.

Please keep all native design files (SolidWorks or Fusion 360 preferred) editable. A short video or animation of the deployment sequence would be a welcome bonus.