Orbital Manufacturing Design Impacts: Small Satellite Refueler Study

In recent years, in-space servicing, assembly, and manufacturing (ISAM) applications have received a notable amount of attention across government, civil, and commercial areas. Enhanced by continued technology development and the integration of previously disparate capability suites, the functionality that can be gained from dynamic and efficient satellite operations drives the value proposition for the implementation of ISAM into routine space mission operations. Concepts for near-term missions include a focus on servicing functions such as refueling for mobility or life extension purposes. Other proposals consider relocation services to reposition satellite assets to meet shifting mission needs. When assessing longer timelines, future mission concepts tend to put a spotlight on the ‘A’ and ‘M’ of ISAM – assembly and manufacturing. Such visions include concepts such as the “Orbital Satellite Factory,” where satellites eventually could be fabricated on orbit, avoiding the complexities that arise from the launch environment. While previous papers have begun assessing and designing the implementation plan for such a concept1, this study instead emphasizes the benefits that could be gained from such an idea. If orbital manufacturing concepts are to be developed, it is integral to stakeholders — from both development and procurement perspectives — to understand the advantages of any design benefits and potential mass savings. In this pursuit, this study assesses the qualitative and quantitative impacts of in-space assembly and manufacturing on the design of a notional small satellite refueler and exemplar large satellites.