Ground Demonstration of Autonomous Robotic Laser Beam Welding for In-Space Servicing, Assembly, and Manufacturing

In-space servicing, assembly, and manufacturing (ISAM) missions require robotic systems that can perform precise joining and repair tasks despite communication latency, thermal variation, diverse lighting conditions, uncertain workpiece geometry, and limited crew intervention. This work presents the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) system, a ground demonstration of autonomous robotic laser beam welding and additive manufacturing capabilities relevant to future ISAM missions. LASAR integrates PickNik MoveIt Pro with the Rocket Lab Robotics xLink robotic arm. Both technologies are also used by NASA’s Fly Foundational Robots mission, establishing a direct connection between terrestrial ISAM testing and future orbital robotic operations. The autonomy architecture combines model-based motion planning, collision-aware trajectory execution, autonomous seam detection, visual servoing for weld-tool alignment, coordinated laser and robot control, and supervisory remote operations. Operators at NASA Johnson Space Center (JSC) remotely commanded experiments performed at NASA Marshall Space Flight Center (MSFC). Thermal-vacuum tests evaluated robotic welding at extreme temperatures from approximately −40 ◦C to 55 ◦C, while additional tests incorporated a wire-feed mechanism for additive deposition and weld repair. The demonstrations advance perception-guided manipulation, remote operations, and in-space welding capabilities needed for scalable ISAM infrastructure.