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NASA NTRSDate not supplied

In-Space Manufacturing

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Zachary Stephen Courtright↗
NASA NTRSDate not supplied

OSAM-2: Plans and Progress for the First Demonstration of Structural Manufacturing in Space

OSAM-2 began as a NASA Space Technology Mission Directorate Tipping Point project in 2016 in which an investment made in ground development and demonstration and/or flight demonstration will result in: Significant advancement of technology’s maturation High likelihood for utilization of technology in commercially fielded space application Significant improvement in ability to successfully bring space technology to market Topic area was “Robotic In-Space Manufacturing and Assembly of Spacecraft and Space Structures” Made In Space, Inc. (now Redwire) proposed Archinaut One, an in-space robotic precision manufacturing and assembly system for larger-than-deployable structures Manufacturing / assembly in the operational environment allows manufactured parts to be designed for that environment (and not for launch loads and need to deploy) In 2020 NASA budget language, NASA began using On-orbit Servicing, Assembly, and Manufacturing Mission 2 (OSAM-2) for Archinaut One Restore-L + SPIDER (SPace Infrastructure DExterous Robot) became OSAM-1 Note: Slide 7 contains video animation, best viewed in presentation mode, run time 2 mins 25 secs.

In-Space Manufacturing↗
NASA NTRS1987

The mechanics of manufacturing in space

The history of the U.S. manned space-flight program is briefly reviewed, with an emphasis on the development of materials-processing technology, and space-manufacturing aspects of the Space Station and proposed lunar and Martian bases are discussed. Consideration is given to the Mercury, Gemini, Apollo, and Apollo-Soyuz missions; Space Shuttle materials-processing experiments; plans for processing electronics crystals, metals, glasses and ceramics, biological materials, and fluids and chemicals on the Space Station; extraction of O2, Fe, Ni, and H2 from lunar materials for use as propellants and in space construction (e.g., of solar power satellites); and the requirements for a permanent base on Mars.

Wade, D. C.↗
NASA NTRS2023

Factories-in-Space for Servicing, Assembly, & Manufacturing

Space 2.0 is a promising frontier for scientific exploration and the advancement of commerce, security, and technology. To effectively harness this potential, it is imperative to establish a multifunctional, resilient, and sustainable infrastructure that enables the maintenance and production of space-based systems. This capability is a driver for mission success on-orbit and for interplanetary travel to other celestial bodies. Central to this infrastructure is the establishment of orbital manufacturing facilities, referred to as 'factories-in-space' (FiS), which serve as critical nodes in the supply chain for the servicing, assembly, and production of systems essential for space-based operations. This paper presents a framework for understanding the key principles and design considerations underpinning FiS.

Technology↗
NASA NTRSDate not supplied

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗
NASA NTRS2019

Additive Manufacturing for Human Space Exploration

NASA’s In Space Manufacturing Initiative (ISM): The Case for ISM - Why; ISM Path to Exploration; In Space Robotic Manufacturing and Assembly (IRMA). Additive Manufacturing (AM) Development For Liquid Rocket Engine Space Flight Hardware. MSFC (Marshall Space Flight Center) Standard and Specification For Additively Manufactured Space Flight Hardware.

Additive Manufacturing Exploration↗
NASA NTRS1998

In-Space Rapid Manufacturing

In-space manufacturing objectives are: (1) Develop and demonstrate capability to directly fabricate components in space using rapid prototyping technology - ceramics (alumina, silicon nitride, zirconia), metallics (stainless, inconel, etc.), high strength/temperature plastics (PEEK). and ABS plastics (starting point). (2) Perform material science experiments on rapid prototyping candidate materials in microgravity.

Cooper, Kenneth G.↗
NASA NTRS1979

Extraterrestrial processing and manufacturing of large space systems. Volume 3: Executive summary

Facilities and equipment are defined for refining processes to commercial grade of lunar material that is delivered to a 'space manufacturing facility' in beneficiated, primary processed quality. The manufacturing facilities and the equipment for producing elements of large space systems from these materials and providing programmatic assessments of the concepts are also defined. In-space production processes of solar cells (by vapor deposition) and arrays, structures and joints, conduits, waveguides, RF equipment radiators, wire cables, converters, and others are described.

Miller, R. H.↗
NASA NTRS1983

The role of simulation prior to manufacturing in space

Prior to manufacturing in space, it is useful to conduct analog experiments where possible so that problems that are apt to be encountered may be identified and planning toward their solution considered. An example is presented involving containerless casting in a near zero gravitational field using paraffin wax as the material cast surrounded by a heated fluid immiscible with the wax that renders it neutrally buoyant.

Shaw, M. C.↗
NASA NTRS1979

Extraterrestrial processing and manufacturing of large space systems, volume 1, chapters 1-6

Space program scenarios for production of large space structures from lunar materials are defined. The concept of the space manufacturing facility (SMF) is presented. The manufacturing processes and equipment for the SMF are defined and the conceptual layouts are described for the production of solar cells and arrays, structures and joints, conduits, waveguides, RF equipment radiators, wire cables, and converters. A 'reference' SMF was designed and its operation requirements are described.

Miller, R. H.↗
NASA NTRS1979

Extraterrestrial processing and manufacturing of large space systems, volume 2, chapters 7-14 and appendices

Production and support equipment specifications are described for the space manufacturing facility (SMF). Defined production equipment includes electromagnetic pumps for liquid metal, metal alloying furnaces, die casters, electron beam welders and cutters, glass forming for structural elements, and rolling. A cost analysis is presented which includes the development, the aquisition of all SMF elements, initial operating cost, maintenance and logistics cost, cost of terrestrial materials, and transportation cost for each major element. Computer program listings and outputs are appended.

Miller, R. H.↗
NASA NTRS1991

Robotics in space-age manufacturing

Robotics technologies are developed to improve manufacturing of space hardware. The following applications of robotics are covered: (1) welding for the space shuttle and space station Freedom programs; (2) manipulation of high-pressure water for shuttle solid rocket booster refurbishment; (3) automating the application of insulation materials; (4) precision application of sealants; and (5) automation of inspection procedures. Commercial robots are used for these development programs, but they are teamed with advanced sensors, process controls, and computer simulation to form highly productive manufacturing systems. Many of the technologies are also being actively pursued in private sector manufacturing operations.

Jones, Chip↗