Solar On-Orbit Welder for Assembly, Repair, and Manufacturing

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. SO-WARM consists of a primary solar concentrator, robotic end effector, part manipulation and structure traversing subsystems, and feedback sensors for non-contact temperature measurements. This combined system enables the welding and joining of metals and non-metal materials using a solar-thermal power source. The system can achieve max temperatures of 2,300 C at the heated target and precision control of these temperatures to within +/-1% for long durations. This innovative technology enables the welding and joining of metals and non-metal materials in space with a significant reduction in electrical power requirements compared to SOA welding technologies. These capabilities come in a lightweight and durable design, keeping sensitive optics at a distance from the heated target to prevent them from fouling or overheating. SO-WARM enables the fabrication of large structures in space as well as servicing, repair, and disassembly of space structures. Phase II technical objectives: 1) Modify the design of SO-WARM for use in relevant space environments 2) Design and fabricate a medium-fidelity system prototype 3) Evaluate weld performance through in-situ monitoring and destructive testing of welded materials 4) Perform zero-gravity and vacuum experiments to raise the TRL of SO-WARM components and subsystems 5) Define SO-WARM space system requirements 6) Initiate development of a SO-WARM digital twin   Proposed deliverables include: 1) Phase II prototype system specifications, drawings, and BOM 2) Evaluation of SO-WARM system performance in a simulated operational environment 3) Evaluation of Ti64 welds produced in vacuum and 0-g, and of 6061Al welds produced in vacuum 4) Summary of tests performed and optimal process parameters identified for each weld configuration and material 5) Metallographic and mechanical test results of welds measuring UTS and fatigue performance 6) List of ISS module and suborbital flight hardware system and integration requirements 7) Description and evaluation of digital twin development   The overall goal of this project is to fabricate a medium-fidelity SO-WARM system and evaluate it in a simulated operational environment. Additional testing will be performed on components and subsystems in microgravity and vacuum conditions. These efforts are aimed at raising the SO-WARM TRL from 4 to 5 in the Phase II.

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.

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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