A classic scene from several high sci-fi movies and shows is when the characters approach their new spaceship in space for the first time. It is typically attached to a massive structure – think of the Kuat Drive Yards in Star Wars or the Utopia Planitia Fleet Yards around Mars in Star Trek. These gigantic structures play a role akin to what dry docks do for modern navies – they allow for the construction of ships in a relatively controlled environment with access to tools and equipment specialized for their construction. That is the idea behind a new NASA Institute for Advanced Concepts (NIAC) grant to ThinkOrbital, a company specializing in In-space assembly, manufacturing, and construction (ISAM&C). Their idea is to build a “Construction Assembly Destination” in orbit to build spacecraft in space.
That might seem like a lofty goal, but ThinkOrbital has some pedigree in doing ISAM&C tasks that no one else has done before. In May 2024, they launched and successfully tested the first-ever weld in space. The mission flew on a Falcon 9, spot-welded together some quarter-inch pieces of aluminum, and returned it to Earth, where the welds were closely examined.
They used a method called electron beam welding, which has several advantages for use in space. First, it doesn’t require as much power as a traditional arc welder—only around 2KW, equivalent to a household iron. Second, it doesn’t create a lot of heat, which can degrade the metal being welded and cause issues like splintering, which can become dangerous in zero-gravity situations.
Video describing the ThinkOrbital welder launch and test.
Credit – ThinkOrbital YouTube Channel
Doing a simple weld is a far cry from building an entire floating dry dock, but it is a step in that direction. Vojtech Holub, ThinkOrbital’s co-founder and CIO, said in an interview with Fraser that the company had actually submitted a proposal to NIAC for a more moderate step in the development of ISAM&C technology. However, the idea for a space station four times the size of the ISS “was not deemed futuristic enough.”
That rejection inspired the company to go bigger – by suggesting an entire orbital construction platform. In the interview, Dr. Holub talks about creating an interior space of 4,000 cubic meters by launching exterior plates akin to the hexagons on a soccer ball and welding them together in space using the company’s existing welder technology. In theory, if the process can be repeated, you could even build a large enough station to make something “up to [the size of] an Imperial Star Destroyer,” according to Dr. Holub.
There are some obvious difficulties in scaling up to that level, including requiring thicker plates and how to introduce gravity to any human occupants. Still, the general idea is scalable well beyond anything currently in orbit. As part of the NIAC grant, Dr. Holub and his team will have to develop a concept of operations (or CONOPS) for the development of the station, including how many launches it would take, what kind of structural loads it would be under, and how it would be assembled once it was up there.
The Orb2 was the original concept, introduced in a paper by Vojtech Holub, that spawned the idea of ThinkOrbital.
Credit – ThinkOrbital YouTube Channel
With answers to those questions in hand, ThinkOrbital would potentially be given a Phase II NIAC grant that would allow them to start building some prototypes to de-risk the technology. But they’ve got to complete Phase I first and compete with plenty of other ideas that NIAC has selected. If they are picked for a Phase II grant, though, it could move the start-up from concept to the reality of building a massive space for constructing space infrastructure – something humanity will need when it expands more throughout the solar system.
Learn More:
NASA / ThinkOrbital – Construction Assembly Destination
Vojtech Holub – Orb2: Spherical Space Station Designed for Single Launch and On-Orbit Assembly
UT – Blue Origin Announces the “Orbital Reef,” the Space Station they Plan to Build in Orbit
UT – Gateway Foundation Gives a Detailed Update on its Voyager Station Concept
Lead Image:
Artist concept highlighting the novel approach proposed by the 2025 NIAC awarded selection of Construction Assembly Destination
Credit – NASA/Ryan Benson/ThinkOrbital
Conclusion
The idea of constructing spacecraft and stations in orbit opens a new frontier in space exploration. It not only proposes a novel way of building structures but also prepares humanity for a sustained presence in space, aiding missions to other celestial bodies.
Table of Technologies Needed for Space Construction
| Technology | Description | Application |
|---|---|---|
| Electron Beam Welding | A welding technique that uses a beam of high-energy electrons to join materials. | Used for creating strong, lightweight joints in spacecraft components. |
| In-Space Assembly | The process of assembling structures in a zero-gravity environment. | Essential for the construction of large-scale space stations. |
| Launch Vehicles | Vehicles designed to deliver payloads into space. | Transport materials and equipment needed for construction. |
| Robotic Systems | Automated systems designed to perform tasks in space. | Assist in the assembly and repair of spacecraft. |
| Adaptable Tools | Tools that can operate effectively in reduced gravity. | Used for various tasks during assembly and maintenance. |
Future Prospects
As companies like ThinkOrbital push the boundaries of what is possible in space construction, we could see a future where spacecraft and habitats are built entirely in orbit. This would not only reduce the cost and complexity of space missions but also expand our capabilities for exploring and colonizing other planets.
Key Innovations to Watch
- Modular Construction Frameworks: Systems that allow pre-fabricated parts to be assembled in zero gravity.
- Advanced Manufacturing Techniques: Techniques such as 3D printing to create on-site resources.
- Life Support Systems: Innovations in maintaining habitable environments for longer missions.
- Transportation Systems: Development of reusable spacecraft designed specifically for orbital operations.
- Teleoperation Technologies: Tools allowing remote operation of equipment for assembly and repairs.
Challenges and Considerations
Despite the exciting prospects, numerous challenges need to be addressed before these visions can become reality:
- Cost: The financial burden of launching materials and technology into space is substantial.
- Technological Gaps: Many critical technologies for efficient in-space construction are still in development stages.
- Safety and Reliability: Ensuring that all systems operate flawlessly in the harsh environment of space.
- Regulatory Issues: Compliance with international space treaties and regulations surrounding orbit operations.
- Environmental Concerns: Understanding the impacts of extended human activity in space.
Further advancements in research, investment, and international collaboration will be pivotal as we strive towards the establishment of space construction capabilities. With every successful step forward, we pave the way for an era of unprecedented exploration and adventure, aiming not just to visit other worlds but to establish a lasting presence among the stars.
Final Thoughts
In summary, the ongoing exploration of space construction technologies signifies a monumental shift in how we view human capabilities beyond Earth. Companies like ThinkOrbital are leading the charge in envisioning a future where the limitations of terrestrial construction do not constrain us. As we look to the stars, the ambition to build our next great vessels among them seems increasingly attainable, fostering not just innovation but a collective spirit of human potential and curiosity.
References
For more information about space shipyards and their potential impacts, explore the following resources:
Lead Image Credit – NASA/Ryan Benson/ThinkOrbital
Ideas presented in this article are reflective of ongoing discussions in the field of aerospace engineering and space exploration, and are subject to investigations by various research initiatives globally.
