Engineering Framework for Assessing Materials and Processes for In-Space Manufacturing

Abstract

In-space manufacturing is a candidate approach for constructing next-generation space structures with larger characteristic dimensions than modern deployable structures. While many construction methods have been proposed, analysis of their performance for building precision structures, such as large-diameter reflectors, is scarce. In this paper, we present a quantitative, system-level comparison of materials and processes for in-space manufacturing. By using performance metrics for thermal stability, resistance to disturbance loads, and minimal-mass buckling strength, we identify candidate feedstock materials. Then, using the metrics of energy consumption and accuracy, we compare candidate processing methods and find that deformation processing is a promising on-orbit manufacturing method. We synthesize the analysis with a case study on the construction of a tetrahedral truss supporting a reflector surface and provide guidelines for assessing materials and processes for in-space manufacturing.