Space manufacturing

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. 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. 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). 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. 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). 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.

Areas In-space manufacturing (ISM) can be categorized into three different areas according to the end use of manufactured products. 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. The Space Studies Institute began hosting a bi-annual Space Manufacturing Conference in 1977 . 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. In this role the shuttle served as an interim, short-duration research platform before the completion of the International Space Station.

… excerpt ends here. Continue reading the full article.