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.