Space manufacturing
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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]
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
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]
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]
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
History
During the
The
The Space Studies Institute began hosting a bi-annual Space Manufacturing Conference in 1977 [citation needed].
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.
In February 1994 and September 1995, the
On May 31, 2005, the recoverable, uncrewed
The completion of the
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.
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
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
Manufacturing
Due to
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
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.
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
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:
- Growth of protein crystals
- Improved semiconductor wafers
- Micro-encapsulation
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,
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
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.See also
- Acid leaching
- Asteroid mining
- In situ resource utilization
- ISS manufacturing
- Self-replication
- Space-based economy
- Space colonization
- Space elevator
- Spacelab
- Varda Space Industries
References
- ^ "Off-Earth manufacturing: using local resources to build a new home". www.esa.int. Retrieved September 9, 2020.
- S2CID 36939988.
- ^ a b c d e f Erik Kulu (September 2022). In-Space Manufacturing - 2022 Industry Survey and Commercial Landscape. 73rd International Astronautical Congress (IAC 2022). Paris, France.
- ^ a b Tracy Prater; Matthew Moraguez (November 11, 2019). In-Space Manufacturing: The Gateway to the High Frontier and an Enabling Technology for Human Space Exploration (PDF). Tennessee Valley Interstellar Workshop. NASA Technical Reports Server (NTRS).
- 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.
- ^ "Columbus laboratory". ESA. July 18, 2007. Retrieved July 18, 2007.
- ^ "General Electric Mark V DS200 DS200SLCCG3A | Automation Industrial". ds200slccg3a.com. Retrieved December 23, 2023.
- ^ "Extraction of Oxygen and Water from Lunar Regolith | NASA SBIR & STTR Program Homepage". sbir.gsfc.nasa.gov. Retrieved December 23, 2023.
- ^ "Breathing Moonrocks". Phys.org. May 8, 2006.
- ^ "Nasa to pay company $1 to collect rocks from moon". December 4, 2020. Retrieved December 23, 2023.
- ^ Dillow, Clay (September 29, 2009). "ISS Could Get its Own Electron-Beam Fabrication 3-D Printer". Popular Science. Retrieved November 24, 2015.
- ^ Basulto, Dominic. (June 26, 2013) Get ready, 3D printing may be coming to a planet near you. The Washington Post. Retrieved on 2015-11-24.
- ^ "NASA to send first 3D printer into space" Archived July 1, 2014, at the Wayback Machine. Madeinspace.us (May 31, 2013). Retrieved on 2015-11-24.
- ^ a b "Additive Manufacturing Facility for ISS: NASA SBIR Phase 2" Archived November 13, 2013, at the Wayback Machine. Madeinspace.us. Retrieved on November 24, 2015.
- ^ Boyle, Alan (June 23, 2016). "NASA picks Firmamentum to build a 3-D printer/recycler for use in space". GeekWire. Retrieved September 21, 2016.
- ^ Clark, Stephen. "Space station receives second of back-to-back cargo deliveries – Spaceflight Now". Retrieved February 11, 2021.
- ^ "3D printer on International Space Station allows astronauts to recycle, reuse, repeat". plasticstoday.com. February 15, 2019. Retrieved February 11, 2021.
- ^ "3D Printing: Food in Space". NASA. May 23, 2013. Retrieved November 24, 2015.
- ^ "In space manufacturing and assembly". Airbus. May 30, 2022. Retrieved June 6, 2022.
- ^ "neofuel home page".
- ^ Skomorohov, Ruslan; Hein, Andreas Makot; Welch, Chris (September 5, 2016). In-orbit Spacecraft Manufacturing: Near-Term Business Cases (Report). International Space University / Initiative for Interstellar Studies.
Further reading
- Andrew H. Cutler, Metallurgical Properties of Lunar and Asteroidal Steels, 7th Princeton/AIAA/SSI Conference, 1985.
- David Gump, Space Enterprise: Beyond NASA, Praeger Publishers, 1990, ISBN 0-275-93314-8.
- T. A. Heppenheimer, Colonies in Space, 1977, Stackpole Books, ISBN 0-8117-0397-5.
- Lewis, J., Matthews, M.S., and Guerrieri, M.L., Editors, 1993, Resources of Near-Earth Space, University of Arizona Press, 1993. ISBN 978-0-8165-1404-5.
- Wahl, Bruno W. (1968). Analysis of Selected Opportunities for Manufacturing in Space. McDonald Douglas Astronautics Company.
External links
- PERMANENT — near-term space resource utilization
- Space Studies Institute
- SKYLAB: A Guidebook (see Chapter 5, section 4)
- Spacehab
- Wake Shield Facility program
- v:Lunar Boom Town A role playing study group at Wikiversity where participants plan and study future space ventures.