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Abstract
Advancements in material science, manufacturing and sensor technologies, Artificial Intelligence, and the Internet of Things have paved the way for fabricating new parts using additive manufacturing in microgravity conditions. NASA has successfully demonstrated 3D printing onboard the International Space Station (ISS), though at a minor scale. Nevertheless, the parts built onboard the ISS were returned to Earth for further testing and verification. The logistics of bi-directional transportation of raw materials from Earth to ISS and 3D-printed parts from ISS back to Earth is complex, expensive, and slow. Harnessing materials from space to establish in-orbit manufacturing as a sustainable process is both technically and economically challenging. The potential to reuse, repurpose or recycle space debris is not well studied, though there is an increasing momentum in Active Debris Removal (ADR) missions. Unlike the standard research or review paper, this is a visionary paper in which the authors explicitly address the intersection between space debris removal and in-space manufacturing. This paper defines a pathway towards implementing an operational in-orbit manufacturing and debris removal model. For the first time, the authors introduce the application of Cloud-Based Design and Manufacturing (CBDM) for in-space manufacturing in this paper. The paper aims to define a roadmap towards implementing a space operational model for in-orbit manufacturing and debris removal. Future enabling technologies that will leverage the advances in robotics, automation, and Space 5.0-based solutions to create a new environmentally friendly and economically profitable orbital ecosystem are presented. The authors analyze the pros and cons of robotic ADR, upcycling and recycling space debris for on-demand manufacturing in orbit and present a systematic approach to implementing in-orbit manufacturing as a new frontier. Recommendations are made to establish an imminent Earth-independent space logistics and supply chain system for operating an orbital factory or warehouse that will help realize a suite of in-orbit manufacturing, maintenance, and assembly missions.
Highlights
Ever since the launch of Sputnik—the first artificial satellite—humanity has witnessed the construction of the biggest orbiting spacecraft - the International Space Station (ISS)—amongst other remarkable accomplishments in space, such as the Apollo lunar mission and a multitude of orbiter and rover missions to the Moon, Mars, asteroids and beyond
Satellites are made of materials that resist, without failure or excessive distortion, the static, dynamic, and thermal stresses that occur during launch, deployment, and service [53–55]
The feedstock needed for on-demand manufacturing of new/replacement parts or components can be produced by repurposing, reusing, or recycling materials in space, including those previously used for packaging or current space debris
Summary
Ever since the launch of Sputnik—the first artificial satellite—humanity has witnessed the construction of the biggest orbiting spacecraft - the International Space Station (ISS)—amongst other remarkable accomplishments in space, such as the Apollo lunar mission and a multitude of orbiter and rover missions to the Moon, Mars, asteroids and beyond. The European Space Agency (ESA) estimates that there are currently 40500 debris objects larger than 10 cm [3] This population already forces satellite operators to adjust course to avoid collisions regularly, and impacts with active satellites have already led to multiple fatalities [4–7]. Experts fear that past a certain threshold, the vast number of debris will trigger a chain collision reaction, referred to as the Kessler syndrome [8] This cascading effect may render low and geostationary orbits (LEO and GEO) non-operational. Space agencies, stakeholders, regulators, investors, businesses, and academia should join forces to develop cutting-edge technologies to robotically upcycle or recycle space debris for on-demand manufacturing in orbit. With space sustainability at the heart of this paper, the potential scientific, environmental, and commercial benefits of additive manufacturing, upcycling, and recycling in orbit and warehouses in space for implementing on-demand design and fabrication services are presented.
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