Scaling Space Structures: A Mass-Efficient Design and Optimization Approach

As space exploration and commercial spaceflight continue to advance, the demand for large, high-precision space structures such as solar arrays, antenna systems, and space-based telescopes has grown significantly. These structures need to be lightweight, stable, and capable of maintaining high surface precision while operating in the harsh dynamic environments of space. The challenges posed by limited mass and volume capacities on launch vehicles, along with the increasing need for larger systems to support ambitious missions, make the design and construction of such large-scale space structures a formidable task. In particular, traditional designs for space-based systems, which often rely on rigid structures and heavy materials, are not optimal for scaling up. As such, there is a pressing need for innovative approaches that prioritize both mass efficiency and performance. This paper presents a solution to these challenges through the development of an advanced optimization framework designed to achieve mass-efficient, high-precision structures for space missions. The focus is on the Tension-Aligned Disc (TAD) architecture, a large-scale system assembled in space using Tubular Truss Additive Manufacturing (TTAM) techniques. The system is optimized to minimize structural mass while meeting several critical requirements, including maintaining high levels of surface precision during operation, achieving mass efficiency greater than traditional designs, and ensuring surface integrity even under various damage scenarios. This innovative design framework is intended to push the boundaries of space structure design, enabling the deployment of large structures that are both lightweight and capable of performing complex tasks in orbit, such as large-scale communications, scientific measurements, and power generation.