Session: 01-03-02: Advanced Manufacturing for Aerospace Structures

Paper Number: 111545

111545 - Roadmap for an Orbital Satellite Factory 

In-space servicing, assembly, and manufacturing (ISAM) is becoming an essential part of the space enterprise. There are efforts underway at NASA, the Space Force, AFRL, DARPA and many private companies to create an in-space economy. There is currently more emphasis on the servicing and assembly, and fewer efforts focused on manufacturing. In some ways, this is a natural balance as it seems likely that servicing and assembly will precede on-orbit manufacturing, and certain elements of servicing and assembly may be essential for on-orbit manufacturing to realize its full potential. However, while the implementation may follow, research to enable future on-orbit manufacturing can begin now to create that capability sooner.

The Aerospace Corporation has developed an Orbital Satellite Factory concept (SciTech, 2023) to accompany their roadmap. This work aims to support the development of autonomous, persistent satellite manufacturing in orbit by 2033. This work describes key elements of that roadmap, which is focused on gaps in current or expected capability. The focus is on basic and applied research, including orbital demonstrations, that is non-duplicative and would be complete by 2029. This team is aware of the many efforts going on in the space, and the intent is to advance research in areas where it is most needed. This would enable an interested customer to post a Request for Proposal confident that the technology has sufficiently advanced.

The roadmap is broken down into 4 different categories, with several tracks for each category and multiple milestones for each track. The 4 categories are: Manufacturing, Inspection, Operations and Design & Analysis. As an example, the Manufacturing track has been broken down further to reflect the primary manufacturing tools incorporated into the Orbital Satellite Factory concept: Fused Filament Fabrication, laser soldering, wire embedding and component placement. The laser soldering track itself is composed of about a dozen milestones, including: developing a process; automating the process; demonstrating operations in vacuum; demonstrating solder dispensing in zero-G; and demonstrating the dispensing and soldering process autonomously on a small satellite. In total, there are over 150 identified milestones in the initial roadmap, with more added regularly as the program becomes better defined. The Inspection category includes tracks for in-situ monitoring, embedded sensors, and non-contact inspection tools. Operations is focused on elements needed to support the manufacturing mission, such as moving parts, controlling attitude, and maintaining the satellite. Design & Analysis contemplates the tools that will be necessary for rapid design of satellites and safe operation of the factory.

Many elements of this roadmap are being pursued at Aerospace and with partners at multiple universities. Ongoing research with the University of Texas at El Paso has led to advances in laser soldering of wires and electronics encapsulated during the 3D printing process. In partnership with USC, researchers are developing primitive commands for orbital robotics that will minimize reaction forces during operations. In collaboration with Cornell University, we have designed a snap-fit spacecraft component that can be manufactured and assembled aboard the International Space Station. Aerospace is shepherding this research while leading our own. Currently we are in the early phases of planning 3 orbital missions to demonstrate technologies important for manufacturing, inspection, or operations. We are creating a new design paradigm to enable the automatic generation of analytical models. This has been demonstrated with structural analysis and is extensible to other disciplines.

As the research progresses, we expect to continuously update the roadmap to reflect progress and problems, helping to identify the next areas of research that need focus.

Presenting Author: Jacob Rome The Aerospace Corporation

Presenting Author Biography: Dr. Jacob Rome has worked at The Aerospace Corporation for over 20 years in the Structures Department. Dr. Rome established himself as an expert in composite structural analysis for structures including solid rocket motors, hypersonic vehicles, clamp band separation systems, payload fairings that incorporated composite sandwich panels and rocket nozzles. Over the past decade, Dr. Rome has taken a leadership role in understanding, evaluating and advancing the use of Additive Manufacturing. This includes an early emphasis on process simulation of additive manufacturing. In recent years, Dr. Rome has stepped forth to become a visionary in the field of In-Space Servicing, Assembly and Manufacturing (ISAM). Dr. Rome's team created a roadmap that could enable an Orbital Satellite Factory within a decade, and he is currently leading a team to shepherd and execute that research within Aerospace and with a half-dozen (and growing) partner universities.

Authors:

Jacob Rome The Aerospace Corporation
Matthew Obenchain The Aerospace Corporation
Kelvin Chen The Aerospace Corporation
Christopher Hartney The Aerospace Corporation
Vinay Goyal The Aerospace Corporation
Alejandro Trujillo The Aerospace Corporation