SBIR-STTR Award

NASA is requesting technologies for Advanced Materials and Manufacturing for In-Space Operations. Blueshift, LLC doing business as Outward Technologies proposes to develop an in-space welding process and robotic system for on-orbit service, assembly, and manufacturing (OSAM) of habitats, space telescopes, antennas, solar array reflectors, and a wide range of potential in-space structures. The proposed process and method utilizes concentrated solar energy (CSE) as the primary power source for the welding and joining of metallic and thermoplastic components in space. Benefits of the proposed innovation include a reduction in electrical power requirements compared to current electron beam and arc welding systems designed for OSAM and further power reduction compared to laser welding systems; a lightweight deployable design that minimizes launch costs; precision spot size and energy flux control enabling precision welds on a wide range of materials, material thicknesses, and joint configurations; and a radiation based welding process that enables welding non-conductive materials including thermoplastics and ceramics while reducing the risk of damaging sensitive electronics that may be close to the weld. The Phase I effort will focus on defining a full-scale SO-WARM system, concept of operations for the full-scale system, and associated subsystem requirements including a well-characterized welding testbed; evaluating different solar concentrator configurations based on mass, launch volume, lifetime/durability, and complexity; quantifying full-scale production rate and functional specifications; and demonstration of the solar welding process in an inert atmosphere through a closed-feedback-loop testbed with three aerospace materials including metals and non-metals. Anticipated

Benefits:
The primary application within NASA’s technology roadmap for SO-WARM is TX12.4: Manufacturing for which the SO-WARM accommodates the desired capabilities outlined in technology candidates TX12.4.1 for in-space fabrication, assembly, and repair. Secondarily, SO-WARM fits into TX13.2: Test and Qualification. SO-WARM can be incorporated into several NASA in-space construction efforts such as OSAM-1, OSAM-2, the lunar Gateway, and the ISS. It can also be used as a free-flying module, servicing satellites and structures as needed on-orbit. There are several applications of the proposed solar welding technology that will benefit the DoD, NSF, and other federal agencies interested in advanced manufacturing techniques. These include a solar welder for use in remote locations on Earth and by underserved communities who may not have access to established infrastructure.

Outward Technologies proposes to continue development of a Solar On-Orbit Welder for Repair, Assembly, and Manufacturing (SO-WARM) to enable In-Space Servicing, Assembly, and Manufacturing (ISAM) for commercial satellites, robotic science, and human exploration. This innovative technology utilizes concentrated solar energy as the primary heat source for welding and joining materials in space. Through continued development, SO-WARM may be used to assemble structures in space, thereby enabling the fabrication of crewed habitats, space telescopes, antennas, and solar array reflectors which are not possible with current technology due to their large size or due to their designs being unable to withstand vibrational loads during launch. Repair of these structures also becomes possible with SO-WARM to mitigate potential damage to structures caused from micrometeorites or orbital debris. These enabling capabilities are made possible through a lightweight, versatile design with significantly reduced electrical power requirements as compared to electron beam, electric arc, or laser power sources. SO-WARM relies on direct solar-thermal heating of materials to weld metals including titanium and aluminum, and join non-metal materials such as PEEK thermoplastic. By relying on the abundant power of the sun, SO-WARM is lightweight, scalable, and versatile to fit the near- and far-term needs of the evolving ISAM market. Results in Phase I showed feasibility of the concept through a low fidelity prototype demonstrating the ability to weld titanium, aluminum, and PEEK. The proposed Phase II will target the design and fabrication of a medium-fidelity SO-WARM system prototype and demonstrating overall performance in a relevant vacuum and microgravity environment, thereby progressing the technology from TRL 4 to 5. These steps are critical for advancing the innovative SO-WARM technology and addressing the growing needs of governments and private companies for ISAM products and services. Anticipated

Benefits:
Potential NASA applications include welding, joining, and repair of structures in space. These enabling capabilities target NASA TX12.4: Manufacturing and TX12.4.1 Manufacturing Processes for in-space fabrication, assembly, and repair. Secondary applications include TX13.2 Test and Qualification through a solar welding testbed on the ISS. SO-WARM may be incorporated into NASA in-space construction efforts such as OSAM-1, OSAM-2, and the lunar Gateway. It can also be used as a free-flying module servicing satellites and structures on-orbit. The SO-WARM technology addresses current and future needs by the DoD and other federal agencies seeking ISAM services and products. Commercial satellites may also be serviced, assembled, and/or repaired using the SO-WARM system and methods. Disassembly of structures in space also becomes possible through solar-thermal melting and vaporization of metals and non-metal materials up to 2,300 C.