The Mechanical Team is responsible for the design, analysis, manufacture, and assembly of the physical structure that holds the satellite and its internal subsystems together. The design is based upon the previously successful AMSAT-NA microsatellites launched in the early 90s, and features a number of modifications better suited to the electronics that will be placed on board and the adaptors used on modern launch providers. BLUEsat also features a number of modifications designed to protect the satellite against the harsh vibrational experience of launch.

BLUEsat is comprised of 5 stacked rectangular trays, or modules, that together with a baseplate form the primary structure for the satellite. Each tray houses some of the satellite's subsystems and payloads. Solar panels are fastened to each side of the structure to give the overall dimensions of around 260mm cubed. A long receiver extends from the top of the structure, while 4 transmitter antennas operate in synchrony from the bottom. This arrangement allows for easy and rapid assembly/disassembly of the entire structure. The empty chassis is shown to the right, where the slots for cable connectors that link the subsystems in each tray together can be seen, as well as the screw holes around the edge of the satellite face where the solar panels will be fastened.

The latest version of the BLUEsat structure was manufactured in 2009. This structure represents the first full-scale flight model of the satellite in our project's history, and as such is a major milestone. During the course of 2009, the structure was subjected to vibrational testing, and we are currently looking forward to incorporating electronic equipment into this testing regime.