SBIR-STTR Award

Made In Space (MIS) is the leader in manufacturing technologies for the outer space environment and has built an Exploration Manufacturing technology portfolio that contains methods for additive, subtractive, and casting manufacturing processes. However, technology advances and system requirements continue to push the boundaries of what is needed by future space explorers and commercial products. Beginning with the Additive Manufacturing Facility (AMF), MIS has progressively pursued additional manufacturing processes using the core subsystems of AMF as a baseline. VULCAN, a metal additive and subtractive manufacturing machine, and EMMA, an electronics manufacturing machine, are two programs that are currently underway. AMF, VULCAN, and EMMA provide a basis for pursuing in-space welding and are used to guide MIS from initial systems requirements development, through creating the critical design of this capability. MIS proposes to develop a Mobile End-effector Laser Device (MELD) capable of on-site, on-demand joining and repair of space structures. MELD is a self-sufficient end-effector that interfaces with a robotic arm and uses the arm for mobility. Key subsystems are directly contained in the end-effector such as power supply, laser system, cooling system, vision system, and avionics. This system is programmed to be autonomous and relies on minimal human interaction, depending on the task. The MELD system provides a tool that applies to many use cases and repair functions that are vital to future long duration exploration missions. Potential NASA Applications (Limit 1500 characters, approximately 150 words) The International Space Station and Lunar Gateway are two large NASA assets that require maintenance due to the environments they are in. Free orbital debris, micrometeorites, and other hazards cause unseen and unplanned damage to the outsides of these habitats and must be considered when human lives are at stake. MELD would be used to remediate any damage that would occur to the external surfaces by either welding over or adding material to the outside of the surface for additional strength and protection. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words) The autonomy provided by the combination of a robotic arm appendage and MELD provide significant cost benefits to mass production and construction companies. High levels of accuracy and precision are two main principles that must be followed with welding and could potentially be disastrous if not achieved. Welding of car struts, foundation beams, and large construction benefit from using MELD.

In-space welding is a valuable manufacturing technology for long duration, long endurance space missions. The Mobile End-effector Laser Device (MELD) is a groundbreaking laser welding system from Made In Space, Inc. (MIS). MELD autonomously welds aerospace-grade metals to assemble large, stable structures on-orbit or on the lunar or Martian surface. These include trusses, arrays, habitats, and pressure vessels. Almost as important, MELD repairs existing structures damaged by micrometeorites or orbital debris without human intervention. MELD offers the only welding and repair system capable of functioning in conditions such as reduced pressure, microgravity, and intense radiation. MELD is a fully functional system containing a laser welding end effector and subsystems including power, cooling, communications, verification and validation, and a foreign object debris collection mechanism. In Phase I, the MELD end effector successfully welded aluminum, stainless steel, titanium, and Inconel alloys. In Phase II, MIS proposes to build a vacuum rated end effector, refine and build optimized subsystems for the relevant testing environment, and continue testing welding both at ambient and in vacuum. Success criteria is the fabrication of welds of correct geometry without cracking or voids. Ground testing includes tensile, hardness, and helium leak testing according to ASTM standards. MIS has extensive experience in developing in-space manufacturing capabilities. MIS has operated multiple payloads on the International Space Station and is currently working on Archinaut, a NASA Tipping Point project, developing a satellite for autonomous in-space manufacturing and assembly. MELD with its welding ability fits well into Archinaut and other MIS efforts to revolutionize living and working in space. Potential NASA Applications (Limit 1500 characters, approximately 150 words) MELD is platform agnostic and benefits several NASA missions. Artemis is one direct mission set that MELD can be utilized upon. When developing the lunar gateway, future habitats on the surface, or exploration vehicles, MELD provides a means for manufacturing and assembling structural segments of each of these. MELD could also be used after the system has been completed to repair or augment the systems with additional supports, patching micrometeroid damage, or adding of functional structures such as antennas or solar array segments. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words) The welding ability of MELD is a valuable addition to the multitude of ongoing or upcoming satellite servicing and repair missions including the DARPA Robotic Servicing of Geosynchronous Satellites (RSGS) mission, and the Northrop Grumman Mission Robotic Vehicle (MRV). As part of these missions, MELD repairs structural damage or welds propulsion or power structures to a damaged vehicle.