SpiderFab(TradeMark):Process for On-Orbit Construction of Kilometer-Scale Apertures

The SpiderFab effort investigated the value proposition and technical feasibility of radically changing the way we build and deploy spacecraft by enabling space systems to fabricate and integrate key components on-orbit. Weeveloped an architecture for a SpiderFab system, identifying the key capabilities, and detailed two concept implementations of this architecture, one specialized for fabricating support trusses for large solar arrays, and the second a robotic system capable of fabricating spacecraft components such as antenna reflectors. We then performed analyses to evaluate the value proposition for on-­orbit fabrication, and in each case found that the dramatic improvements in structural performance and packing efficiency enabled by on-orbit fabrication can provide order-of-magnitude improvements in key system metrics. For phased-­‐array radars, SpiderFab enables order-­of-­magnitude increases in gain-per-stowed-volume. For the New Worlds Observer mission, SpiderFab construction of a starshade can provide a ten-fold increase in the number of Earth-like planets discovered per dollar. For communications systems, SpiderFab can change the cost equation for large antenna reflectors, enabling affordable deployment of much larger apertures than feasible with current deployable technologies. To establish the technical feasibility, we identified methods for combining several additive manufacturing technologies with robotic assembly technologies, metrology sensors, and thermal control techniques to provide the capabilities required to implement a SpiderFab system. We performed proof-­of-concept level testing of these approaches, in each case demonstrating that the proposed solutions are feasible, and establishing the SpiderFab architecture at TRL-3. Further maturation of SpiderFab to mission-readiness is well-suited to an incremental development program. Affordable smallsat demonstrations will prepare the technology for full-scale demonstration that will unlock the full potential of the SpiderFab architecture by flight qualifying and validating an on-orbit fabrication and integration process that can be re-used to reduce the life-cycle cost and increase power, bandwidth, resolution, and sensitivity for a wide range of NASA Science and Exploration missions.