(The full project with pictures is here: https://drive.google.com/file/d/1C6C5ds-iacaaRa0cLAPL-m38w__rIebx/view?usp=sharing )

What did you develop? 

The T.O.A.S2.T. (Tinned Origami Architecture for Space Smart Tending) project is an in-space dockyard capable to build up small, medium and large space-devoted frames. It is integrated into a launch (from Earth) – docking – assembly – verification – delivery full process, thanks to which the single components are turned into a whole structure. Such architecture implements an innovative assembly paradigm based on the use of space-grade adhesive joints, reducing the mechanical connection complexity among integrated modules and sub-systems. It makes use of an “industrial” logistic, in order to achieve in-space assembly and test of custom or series production components. It takes place on a flat origami-based and sandwich-like deployable platform unfolded by a foam inflatable balloon.

The full procedure is electrically powered by a NASA® Starshade-like (https://exoplanets.nasa.gov/resources/1015/flower-power-nasa-reveals-spring-starshade-animation/ ) solar panels cluster. It starts with the docking phase between the full-of-components tanks. These latter come from Earth and are grabbed by dedicated telescopic arms, which store them into deployable-truss bays. 

Each bay is planned as “hot-spot” where specialized multiaxial robots automatically actuate the assembly/verification procedure(e.g. from https://www.universal-robots.com/). Such robots are mounted on a conveyor belt, that allows the base translation, and host a variety of different end-effectors (e.g. gripper, dispensers, calipers, gauges, sensors) useful for the building procedure. Moreover, they are controlled by a pre-programmed sequential code, customized for the specific purpose, developed and transferred by the space agency, contractors or sub-contractors. A dedicated region is also provided for the additive manufacturing of customized metallic parts (https://www.esa.int/Enabling_Support/Space_Engineering_Technology/Advanced_Manufacturing, https://cdn2.b2match.io/event/3084/assets/8475250769-d3b6fe41d5.pdf, https://artes.esa.int/news/additive-manufacturing-%E2%80%93-making-impossible-possible-3d-printing ) if nedeed.

An inflatable and habitable service module (Nasa® LISA-like https://ntrs.nasa.gov/citations/20180007255 or Nasa® Bigelow-like https://www.space.com/bigelow-aerospace-space-habitat-nasa-test.html ) is also included into the architectural concept for manned operations (e.g. E.V.A for maintenance interventions) as well as a transit station for future space life. 

Why is it important? 

A huge and significant step forward into the exploration and colonization of the fourth ambient (near and outer space) will be accessible from the in-orbit manufacturing and the assembly of space components into entire, complex and multi-purpose structures (e.g. habitable modules). This spirit is also shared from the Italian Centre for Near Space (CNS) involved into different project as Orbitecture (https://www.instituteforthefuture.it/wp-content/uploads/2019/10/CNS-Vision.pdf ), a space dome for the cis-lunar conquest.

The proposed space platform (the dockyard) fits into the mentioned framework and introduces multiple and important innovation sources. First of all, the use of effective and reliable space-grade adhesive joints, rather than classical mechanical fasteners, permits to shift most of the assembly-verification procedure from Earth to a space orbit, being the influence of the launch environment on the separated items less severe. This is particularly relevant for the launch vehicle requirements (e.g. frequency requirement). Starting from this consideration, multiple launches can be planned, reducing the time and cost associated to the verification and test of the structural part. This idea is supported by the by-now developed technology of reusable rockets, avoiding the launcher wastefulness and relative costs too. Additionally, the use of reliable space-grade adhesive joints is a promising technology also in case of disassembly needs. In fact, by means of mechanical cutter, attached on the multiaxial robots, they can be easily removed.

Subsequently, the proposed architecture implements a new deployment concept based on the coupling of a foam inflatable balloon with an origami unfoldable structure, preventing complex and actuated systems and permitting to save mass and volume at the launch phase.

In addition, the developed source of innovation is represented by the launch (from Earth) – docking – assembly – verification – delivery full process which is accessible with the nowadays technological capabilities in the framework of an in-space industry. All space agencies or independent entrepreneurs will benefit from this infrastructure, even only for in-space substitution of a single broken component, without threaten the success of the whole mission.

What does it do?

The primary task that the platform has to fulfil is the assembly-verification procedure. Being the docking phase a well-established procedure, currently adopted from now-a-days space platform, the fundamental duty consists on the capability of the entire build-up sequence. It has to make available a consistent spacecraft as the outcome of entire cycle, storing in proper bays the components. More specifically, the multiaxial robots have to pick up the right components, satisfying the mechanical positioning requirements, and join them together with the mentioned space-grade adhesive joints avoiding the use of classical mechanical fasteners that could be difficult to manage in gravity absence. The proposed architecture has also to be capable to provide and operate verification procedure during the assembly and in a dedicated bay. The additional service inflatable module has to be capable to host astronauts for EVA operations, proving the environmental conditions for life in space.

How does it work?

Different steps are required to permit the practical use of this conceptual study: 0. A preliminary phase requires to put into orbit the T.O.A.S2.T. infrastructure. A first launch will be necessary to put into orbit the sandwich-like structure which is in a folded configuration, stowed into the launcher. Once in orbit, the balloon is inflated and the origami is deployed. Ulterior launches will be required to the assembly of the bays, the inflatable service module and the multiaxial robots. This step, here not investigated in details, is mandatory for the fulfilment of the entire technological process; 1. Small and compact modules, the full-of-components cargo, are send into space. Once approached to the space architecture (rendezvous), telescopic arms capture them, performing a selective docking based on the contained components or sub-system (e.g. thermal, electrical, structural…); 2. Automatic robots download the content of a cargo into the bay for storage and assembly purposes; 3. Once empty, the modules are detached from the bays, performing the undocking procedure. They are ready to re-enter into the Earth atmosphere; 4. The assembly process can start. From the first to the last bay, dedicated multiaxial robots perform the assembly of the whole structure adopting space-grade adhesive bonding; 5. The verification process (e.g. optics alignment, mechanical tolerances) takes place during the assembly procedure for dedicated equipment and into a dedicated bay for the whole space structure; 6. Once the process is terminated, the structure is located on a near waiting region to start its mission;

An additional step can be taken into account if needed, i.e. the astronaut maintenance operations in case of issues.

The assembly architecture can also work as a disassembly platform using dedicated mechanical cutters to remove the adhesive layers and separate each sub-system putting them into the cargo modules. The electrical supplying is made available from a NASA® Starshade-like origami structure. It is a cluster of solar panels embedded on a flower-based deployable structure which occupy low volumes when stowed and high irradiated surface when deployed.

What do you hope to achieve?

Through the proposed compact infrastructure, which occupy low volume at launch, we intend to achieve an innovative and feasible space platform thanks to which: the production will be accessible shifting it from Earth to a space orbit and the costs related to the verification and design process on the ground will be reduced.