Space manufacturing or In-space manufacturing (ISM in short) is the fabrication, assembly or integration of tangible goods beyond Earth's atmosphere (or more generally, outside a planetary atmosphere), involving the transformation of raw or recycled materials into components, products, or infrastructure in space, where the manufacturing process is executed either by humans or automated systems by taking advantage of the unique characteristics of space.[3] Synonyms of Space/In-space manufacturing are In-orbit manufacturing (since most production capabilities are limited to low Earth orbit), Off-Earth manufacturing, Space-based manufacturing, Orbital manufacturing, In-situ manufacturing, In-space fabrication, In-space production, etc.[3] In-space manufacturing is a part of the broader activity of in-space servicing, assembly and manufacturing (ISAM) and is related to in situ resource utilization (ISRU).[3]
Three major domains of In-space manufacturing are ISM for space (space-for-space) where products remain in space, ISM for Earth (space-for-Earth) where goods with improved properties produced in outer-space microgravity are transported back to Earth, and ISM for surface where goods are produced on or sent to surfaces of celestial bodies like the Moon, Mars, and asteroids.[3]
In-space manufacturing uses processes such as additive manufacturing (printing a 3D object in successive layers), subtractive manufacturing (making 3D objects by successively removing material from a solid), hybrid manufacturing (usually combining additive manufacturing and subtractive manufacturing) and welding (joining pieces of material by melting or plasticizing along a joint line).[4]
In-space manufacturing removes spacecraft design limitations due to launch parameters (mass, vibration, structural load, etc.) and volume limitations imposed by payload size. It allows for recycling of launched materials, utilization space-mined resources and on-demand spare parts production, which enables on-site repair of critical parts (increasing reliability and redundancy) and infrastructure development. It takes advantage of unique space features such as microgravity, ultra-vacuum and containerless processing, which are difficult to do on Earth.[3][4]
Areas
In-space manufacturing (ISM) can be categorized into three different areas according to the end use of manufactured products.[3] In-space manufacturing for space (space-for-space) involves activities focused on in-orbit construction intended for use in space. ISM for Earth (space-for-Earth) is the production of new materials and products that exhibit enhanced properties when manufactured in microgravity, subsequently transported back to Earth. Lastly, ISM for surface extends to surface operations on celestial bodies such as the Moon, Mars, and asteroids.
Rationale
There are several motivating factors behind in-space manufacturing. The space environment, in particular the effects of microgravity and vacuum, enable the research of and production of goods that could otherwise not be manufactured on Earth. Secondly, the extraction and processing of raw materials from other astronomical bodies, also called In-Situ Resource Utilisation (ISRU), could enable more sustainable space exploration missions at reduced cost compared to launching all required resources from Earth. Furthermore, raw materials could be transported to low Earth orbit where they could be processed into goods that are shipped to Earth. By replacing terrestrial production on Earth, this seeks to preserve the Earth. Moreover, raw materials of very high value, for example gold, silver, or platinum, could be transported to low Earth orbit for processing or transfer to Earth which is thought to have the potential to become economically viable. In-space manufacturing supports long-duration space missions and colonization by enabling on-site repair and infrastructure development beyond Earth. Additionally, in the area of spaceflight technology, space manufacturing enhances mission safety by decentralizing manufacturing activities and establishing redundancy in critical systems, allows for customized production tailored to specific mission requirements, fostering rapid iteration and adaptation of designs, drives technological innovation in materials science, robotics, and additive manufacturing, with applications extending beyond space exploration, and lays the foundation for space-based infrastructure development, supporting a wide range of commercial activities and scientific research.
History
During the Soyuz 6 mission of 1969, Russian cosmonauts performed the first welding experiments in space. Three different welding processes were tested using a hardware unit called Vulkan. The tests included welding aluminum, titanium, and stainless steel.
The Skylab mission, launched in May 1973, served as a laboratory to perform various space manufacturing experiments. The station was equipped with a materials processing facility that included a multi-purpose electric furnace, a crystal growth chamber, and an electron beam gun. Among the experiments to be performed was research on molten metal processing; photographing the behavior of ignited materials in zero-gravity; crystal growth; processing of immiscible alloys; brazing of stainless steel tubes, electron beam welding, and the formation of spheres from molten metal. The crew spent a total of 32 man-hours on materials science and space manufacturing investigation during the mission.
Microgravity research in materials processing continued in 1983 using the Spacelab facility. This module has been carried into orbit 26 times aboard the Space Shuttle, as of 2002[update]. In this role the shuttle served as an interim, short-duration research platform before the completion of the International Space Station.
The Wake Shield Facility is deployed by the Space Shuttle's robotic arm. NASA image
In February 1994 and September 1995, the Wake Shield Facility was carried into orbit by the Space Shuttle. This demonstration platform used the vacuum created in the orbital wake to manufacture thin films of gallium arsenide and aluminum gallium arsenide.
On May 31, 2005, the recoverable, uncrewed Foton-M2 laboratory was launched into orbit. Among the experiments were crystal growth and the behavior of molten-metal in weightlessness.
The completion of the International Space Station has provided expanded and improved facilities for performing industrial research. These have and will continue to lead to improvements in our knowledge of materials sciences, new manufacturing techniques on Earth, and potentially some important discoveries in space manufacturing methods. NASA and Tethers Unlimited will test the Refabricator aboard the ISS, which is intended to recycle plastic for use in space additive manufacturing.[5]
The Material Science Laboratory Electromagnetic Levitator (MSL-EML) on board the Columbus Laboratory is a science facility that can be used to study the melting and solidification properties of various materials. The Fluid Science Laboratory (FSL) is used to study the behavior of liquids in microgravity.[6]
Material properties in the space environment
There are several unique differences between the properties of materials in space compared to the same materials on the Earth. These differences can be exploited to produce unique or improved manufacturing techniques.
The microgravity environment allows control of convection in liquids or gasses, and the elimination of sedimentation. Diffusion becomes the primary means of material mixing, allowing otherwise immiscible materials to be intermixed.
The environment allows enhanced growth of larger, higher-quality crystals in solution.
The ultraclean vacuum of space allows the creation of very pure materials and objects. The use of vapor deposition can be used to build up materials layer by layer, free from defects.
Surface tension causes liquids in microgravity to form perfectly round spheres. This can cause problems when trying to pump liquids through a conduit, but it is very useful when perfect spheres of consistent size are needed for an application.
Space can provide readily available extremes of heat and cold. Sunlight can be focused to concentrate enough heat to melt the materials, while objects kept in perpetual shade are exposed to temperatures close to absolute zero. The temperature gradient can be exploited to produce strong, glassy materials.
Material processing
For most manufacturing applications, specific material requirements must be satisfied. Mineralores need to be refined to extract specific metals, and volatile organic compounds will need to be purified. Ideally these raw materials are delivered to the processing site in an economical manner, where time to arrival, propulsionenergy expenditure, and extraction costs are factored into the planning process. Minerals can be obtained from asteroids, the lunar surface, or a planetary body. Volatiles could potentially be obtained from a comet, carbonaceous chondrite or "C-Type" asteroids, or the moons of Mars or other planets. It may also prove possible to extract hydrogen in the form of water ice or hydrated minerals from cold traps on the poles of the Moon.
Unless the materials processing and the manufacturing sites are co-located with the resource extraction facilities, the raw materials would need to be moved about the Solar System. There are several proposed means of providing propulsion for this material, including solar sails, electric sails, magnetic sails, electric ion thrusters, microwave electrothermal thrusters, or mass drivers (this last method uses a sequence of electromagnets mounted in a line to accelerate a conducting material).
At the materials processing facility, the incoming materials will need to be captured by some means. Maneuvering rockets attached to the load can park the content in a matching orbit. Alternatively, if the load is moving at a low delta-v relative to the destination, then it can be captured by means of a mass catcher. This could consist of a large, flexible net or inflatable structure that would transfer the momentum of the mass to the larger facility. Once in place, the materials can be moved into place by mechanical means or by means of small thrusters.
Materials can be used for manufacturing either in their raw form, or by processing them to extract the constituent elements. Processing techniques include various chemical, thermal, electrolytic, and magnetic methods for separation. In the near term, relatively straightforward methods can be used to extract aluminum, iron, oxygen, and silicon from lunar and asteroidal sources. Less concentrated elements will likely require more advanced processing facilities, which may have to wait until a space manufacturing infrastructure is fully developed.[7]
Some of the chemical processes will require a source of hydrogen for the production of water and acid mixtures. Hydrogen gas can also be used to extract oxygen from the lunar regolith, although the process is not very efficient.[clarification needed][8] So a readily available source of useful volatiles is a positive factor in the development of space manufacturing. Alternatively, oxygen can be liberated from the lunar regolith without reusing any imported materials by heating the regolith to 4,530°F (2,500°C) in a vacuum. This was tested on Earth with lunar simulant in a vacuum chamber. As much as 20% of the sample was released as free oxygen. Eric Cardiff calls the remainder slag. This process is highly efficient in terms of imported materials used up per batch, but is not the most efficient process in energy per kilogram of oxygen.[9]
One proposed method of purifying asteroid materials is through the use of carbon monoxide (CO). Heating the material to 500°F (260°C) and exposing it to CO causes the metals to form gaseous carbonyls. This vapor can then be distilled to separate out the metal components, and the CO can then be recovered by another heating cycle. Thus an automated ship can scrape up loose surface materials from, say, the relatively nearby 4660 Nereus (in delta-v terms), process the ore using solar heating and CO, and eventually return with a load of almost pure metal. The economics of this process can potentially allow the material to be extracted at one-twentieth the cost of launching from Earth, but it would require a two-year round trip to return any mined ore.[10]
Manufacturing
Due to speed of light constraints on communication, manufacturing in space at a distant point of resource acquisition will either require completely autonomous robotics to perform the labor, or a human crew with all the accompanying habitat and safety requirements. If the plant is built in orbit around the Earth, or near a crewed space habitat, however, telerobotic devices can be used for certain tasks that require human intelligence and flexibility.
Solar power provides a readily available power source for thermal processing. Even with heat alone, simple thermally-fused materials can be used for basic construction of stable structures. Bulk soil from the Moon or asteroids has a very low water content, and when melted to form glassy materials is very durable. These simple, glassy solids can be used for the assembly of habitats on the surface of the Moon or elsewhere. The solar energy can be concentrated in the manufacturing area using an array of steerable mirrors.
The availability and favorable physical properties of metals will make them a major component of space manufacturing. Most of the metal handling techniques used on Earth can also be adopted for space manufacturing. A few of these techniques will need significant modifications due to the microgravity environment.
The production of hardened steel in space will introduce some new factors. Carbon only appears in small proportions in lunar surface materials and will need to be delivered from elsewhere. Waste materials carried by humans from the Earth is one possible source, as are comets. The water normally used to quench steel will also be in short supply, and require strong agitation.
Casting steel can be a difficult process in microgravity, requiring special heating and injection processes, or spin forming. Heating can be performed using sunlight combined with electrical heaters. The casting process would also need to be managed to avoid the formation of voids as the steel cools and shrinks.
Various metal-working techniques can be used to shape the metal into the desired form. The standard methods are casting, drawing, forging, machining, rolling, and welding. Both rolling and drawing metals require heating and subsequent cooling. Forging and extrusion can require powered presses, as gravity is not available. Electron beam welding has already been demonstrated on board the Skylab, and will probably be the method of choice in space. Machining operations can require precision tools which will need to be imported from the Earth for some duration.
New space manufacturing technologies are being studied at places such as Marshall's National Center for Advanced Manufacturing. The methods being investigated include coatings that can be sprayed on surfaces in space using a combination of heat and kinetic energy, and electron beam free form fabrication[11] of parts. Approaches such as these, as well as examination of material properties that can be investigated in an orbiting laboratory, will be studied on the International Space Station by NASA and Made In Space, Inc.[12]
3D-printing in space
The option of 3D printing items in space holds many advantages over manufacturing situated on Earth. With 3D printing technologies, rather than exporting tools and equipment from Earth into space, astronauts have the option to manufacture needed items directly. On-demand patterns of manufacturing make long-distance space travel more feasible and self-sufficient as space excursions require less cargo. Mission safety is also improved.
The Made In Space, Inc.3D printers, which launched in 2014 to the International Space Station, are designed specifically for a zero-gravity or micro-gravity environment. The effort was awarded the Phase III Small Business Innovation and Research Contract.[13] The Additive Manufacturing Facility will be used by NASA to carry out repairs (including during emergency situations), upgrades, and installation.[14] Made In Space lists the advantages of 3D printing as easy customization, minimal raw material waste, optimized parts, faster production time, integrated electronics, limited human interaction, and option to modify the printing process.[14]
The Refabricator experiment, under development by Firmamentum, a division of Tethers Unlimited, Inc. under a NASA Phase III Small Business Innovation Research contract, combines a recycling system and a 3D printer to perform demonstration of closed-cycle in-space manufacturing on the International Space Station (ISS).[15] The Refabricator experiment, which was delivered to the ISS aboard Cygnus NG-10 on November 19, 2018,[16] processes plastic feedstock through multiple printing and recycling cycles to evaluate how many times the plastic materials can be re-used in the microgravity environment before their polymers degrade to unacceptable levels.[17]
Additionally, 3D printing in space can also account for the printing of meals. NASA's Advanced Food Technology program is currently investigating the possibility of printing food items in order to improve food quality, nutrient content, and variety.[18]
Airbus is developing and planning with the European Space Agency to send and test the first 3D-printer printing metals in space at the ISS in a year from 2022, and establishing space manufacturing in three to four years from 2022.[19]
Products
There are thought to be a number of useful products that can potentially be manufactured in space and result in an economic benefit. Research and development is required to determine the best commodities to be produced, and to find efficient production methods. The following products are considered prospective early candidates:
As the infrastructure is developed and the cost of assembly drops, some of the manufacturing capacity can be directed toward the development of expanded facilities in space, including larger scale manufacturing plants. These will likely require the use of lunar and asteroid materials, and so follow the development of mining bases.
Rock is the simplest product, and at minimum is useful for radiation shielding. It can also be subsequently processed to extract elements for various uses.
Water from lunar sources, Near Earth Asteroids or Martian moons is thought to be relatively cheap and simple to extract, and gives adequate performance for many manufacturing and material shipping purposes. Separation of water into hydrogen and oxygen can be easily performed in small scale, but some scientists[20] believe that this will not be performed on any large scale initially due to the large quantity of equipment and electrical energy needed to split water and liquify the resultant gases. Water used in steam rockets gives a specific impulse of about 190 seconds;[citation needed] less than half that of hydrogen/oxygen, but this is adequate for delta-v's that are found between Mars and Earth.[citation needed] Water is useful as a radiation shield and in many chemical processes.
Ceramics made from lunar or asteroid soil can be employed for a variety of manufacturing purposes.[citation needed] These uses include various thermal and electrical insulators, such as heat shields for payloads being delivered to the Earth's surface.
Metals can be used to assemble a variety of useful products, including sealed containers (such as tanks and pipes), mirrors for focusing sunlight, and thermal radiators. The use of metals for electrical devices would require insulators for the wires, so a flexible insulating material such as plastic or fiberglass will be needed.
A notable output of space manufacturing is expected to be solar panels. Expansive solar energy arrays can be constructed and assembled in space. As the structure does not need to support the loads that would be experienced on Earth, huge arrays can be assembled out of proportionately smaller amounts of material. The generated energy can then be used to power manufacturing facilities, habitats, spacecraft, lunar bases, and even beamed down to collectors on the Earth with microwaves.
Other possibilities for space manufacturing include propellants for spacecraft, some repair parts for spacecraft and space habitats, and, of course, larger factories.[21] Ultimately, space manufacturing facilities can hypothetically become nearly self-sustaining, requiring only minimal imports from the Earth. The microgravity environment allows for new possibilities in construction on a massive scale, including megascale engineering. These future projects might potentially assemble space elevators, massive solar array farms, very high capacity spacecraft, and rotating habitats capable of sustaining populations of tens of thousands of people in Earth-like conditions.
Challenges
The space environment is expected to be beneficial for production of a variety of products assuming the obstacles to it can be overcome. The most significant cost is overcoming the energy hurdle for boosting materials into orbit. Once this barrier is significantly reduced in cost per kilogram, the entry price for space manufacturing can make it much more attractive to entrepreneurs. After the heavy capitalization costs of assembling the mining and manufacturing facilities are paid, the production will need to be economically profitable in order to become self-sustaining and beneficial to society.
The economic requirements of space manufacturing imply a need to collect the requisite raw materials at a minimum energy cost. The cost of space transport is directly related to the delta-v, or change in velocity required to move from the mining sites to the manufacturing plants. Bringing material to Earth orbit from bodies such as Near-Earth asteroids, Phobos, Deimos or the lunar surface requires far less delta-v than launching from Earth itself, despite the greater distances involved. This makes these places economically attractive as sources of raw materials.
A space settlement is a settlement in outer space, sustaining more extensively habitation facilities in space than a general space station or spacecraft. Possibly including closed ecological systems, its particular purpose is permanent habitation.
In space exploration, in situ resource utilization (ISRU) is the practice of collection, processing, storing and use of materials found or manufactured on other astronomical objects that replace materials that would otherwise be brought from Earth.
Electron-beam additive manufacturing, or electron-beam melting (EBM) is a type of additive manufacturing, or 3D printing, for metal parts. The raw material is placed under a vacuum and fused together from heating by an electron beam. This technique is distinct from selective laser sintering as the raw material fuses have completely melted. Selective Electron Beam Melting (SEBM) emerged as a powder bed-based additive manufacturing (AM) technology and was brought to market in 1997 by Arcam AB Corporation headquartered in Sweden.
Laser bonding is a marking technique that uses lasers to bond an additive marking substance to a substrate.
Space architecture is the theory and practice of designing and building inhabited environments in outer space. This mission statement for space architecture was developed in 2002 by participants in the 1st Space Architecture Symposium, organized at the World Space Congress in Houston, by the Aerospace Architecture Subcommittee, Design Engineering Technical Committee (DETC), American Institute of Aeronautics and Astronautics (AIAA).
Electron-beam freeform fabrication (EBF3) is an additive manufacturing process that builds near-net-shape parts. It requires far less raw material and finish machining than traditional manufacturing methods. EBF3 is done in a vacuum chamber where an electron beam is focused on a constantly feeding source of metal, which is melted and applied as called for by a three-dimensional layered drawing - one layer at a time - on top of a rotating metallic substrate until the part is complete.
Asteroid capture is an orbital insertion of an asteroid around a larger planetary body. When asteroids, small rocky bodies in space, are captured, they become natural satellites, specifically either an irregular moon if permanently captured, or a temporary satellite.
Selective laser melting (SLM) is one of many proprietary names for a metal additive manufacturing (AM) technology that uses a bed of powder with a source of heat to create metal parts. Also known as direct metal laser sintering (DMLS), the ASTM standard term is powder bed fusion (PBF). PBF is a rapid prototyping, 3D printing, or additive manufacturing technique designed to use a high power-density laser to melt and fuse metallic powders together.
Space farming refers to the cultivation of crops for food and other materials in space or on off-Earth celestial objects – equivalent to agriculture on Moon.
SpaceX CRS-4, also known as SpX-4, was a Commercial Resupply Service mission to the International Space Station (ISS), contracted to NASA, which was launched on 21 September 2014 and arrived at the space station on 23 September 2014. It was the sixth flight for SpaceX's uncrewed Dragon cargo spacecraft, and the fourth SpaceX operational mission contracted to NASA under a Commercial Resupply Services contract. The mission brought equipment and supplies to the space station, including the first 3D printer to be tested in space, a device to measure wind speed on Earth, and small satellites to be launched from the station. It also brought 20 mice for long-term research aboard the ISS.
Construction 3D Printing (c3Dp) or 3D construction Printing (3DCP) refers to various technologies that use 3D printing as a core method to fabricate buildings or construction components. Alternative terms for this process include "additive construction." "3D Concrete" refers to concrete extrusion technologies whereas Autonomous Robotic Construction System (ARCS), large-scale additive manufacturing (LSAM), and freeform construction (FC) refer to other sub-groups.
Sciaky, Inc. is an American manufacturer of metal 3D printing systems and industrial welding systems, founded in 1939 and headquartered in Chicago, Illinois. It specializes in electron beam welding systems and services for aerospace manufacturers.
Made In Space, Inc., is an American company specializing in the engineering and manufacturing of three-dimensional printers for use in microgravity. Headquartered in Jacksonville, Florida, Made In Space's 3D printer was the first manufacturing device used in space.
BioSentinel is a lowcost CubeSat spacecraft on a astrobiology mission that will use budding yeast to detect, measure, and compare the impact of deep space radiation on DNA repair over long time beyond low Earth orbit.
As the space race came to an end, a new rationale for investment in space exploration emerged, focused on the pragmatic use of space for improving life on Earth. The legacy of the space race is that nations continue to pursue space exploration to enhance their prestige. As the justification for government-funded space programs shifted to "the public good", space agencies began to articulate and measure the wider socio-economic benefits that might derive from their activities, including both the direct and indirect benefits of space exploration. However, such programs have also been criticized with several drawbacks cited.
The ISS U.S. National Lab, commonly known as the ISS National Lab, is a U.S. government-funded national laboratory established on 30 December 2005 by the 2005 NASA Authorization Act. With principal research facilities located in the United States Orbital Segment (USOS) of the International Space Station (ISS), the Laboratory conducts research in life sciences, physical sciences, technology development and remote sensing for a broad range of academic, government and commercial users. Of the 270 payloads that the Center for the Advancement of Science in Space (CASIS) has sent to the ISS, 176 have been for commercial companies including Merck & Co., Novartis, Eli Lilly and Company, Hewlett Packard Enterprise, Honeywell, and Procter & Gamble.
The Moon bears substantial natural resources which could be exploited in the future. Potential lunar resources may encompass processable materials such as volatiles and minerals, along with geologic structures such as lava tubes that, together, might enable lunar habitation. The use of resources on the Moon may provide a means of reducing the cost and risk of lunar exploration and beyond.
SpaceX CRS-24, also known as SpX-24, was a Commercial Resupply Service mission to the International Space Station launched on 21 December 2021, at 10:07:08 UTC. The mission is contracted by NASA and is flown by SpaceX using a Cargo Dragon. This is the fourth flight for SpaceX under NASA's CRS Phase 2 contract awarded in January 2016.
Microgravity bioprinting is the utilization of 3D bioprinting techniques under microgravity conditions to fabricate highly complex, functional tissue and organ structures. The zero gravity environment circumvents some of the current limitations of bioprinting on Earth including magnetic field disruption and biostructure retention during the printing process. Microgravity bioprinting is one of the initial steps to advancing in space exploration and colonization while furthering the possibilities of regenerative medicine.
NG-20 was the twentieth flight of the Cygnus, an expendable American cargo spacecraft used for International Space Station (ISS) logistics missions that launched on 30 January 2024 and was deorbited on 13 July 2024. It was operated by Northrop Grumman under a Commercial Resupply Services contract with NASA. The spacecraft was an Enhanced Cygnus, named the S.S. Patricia "Patty" Hilliard Robertson in honor of the NASA astronaut who died in a plane crash prior to being assigned to a crew to fly to the ISS.
1 2 3 4 5 6 Erik Kulu (September 2022). In-Space Manufacturing - 2022 Industry Survey and Commercial Landscape. 73rd International Astronautical Congress (IAC 2022). Paris, France.
↑ Carreau, Mark (November 14, 2018). "ISS Cargo Missions To Test Soyuz, Deliver New Science". Aviation Week. Researchers from NASA and Tethers Unlimited Inc., of Bothell, Washington, are collaborating as well on the demonstration of a Refabricator. The small, refrigerator-sized device is intended to recycle plastic waste, including packing materials, bags and food containers into feed stock for the space additive manufacturing, or 3D printing, of replacement parts and other equipment that would otherwise require launch mass and volume.
v:Lunar Boom Town A role playing study group at Wikiversity where participants plan and study future space ventures.
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