In-orbit manufacturing and inspection technology development

TWI is advancing the technologies that will enable manufacturing, assembly, and inspection directly in orbit — helping pave the way for sustainable, repairable, and evolvable space infrastructures.

Building on our heritage in welding, coating, and non-destructive testing (NDT) for extreme environments, we are developing and adapting processes that can operate in vacuum, microgravity, and thermal cycling conditions. These include electron beam (EB) welding, friction-based joining, additive deposition, and remote robotic inspection systems suitable for satellites, space stations, and large orbital structures.

Key focus areas

• In-orbit welding and joining: adaptation of electron beam, laser, and friction processes for autonomous operation in vacuum environments.

• Additive and coating processes: metal and composite deposition for structural repair, reinforcement, and functional coating in orbit.

• In-situ inspection and sensing: development of compact, autonomous NDT systems (e.g. laser ultrasonics, shearography, and eddy current sensors) for on-orbit verification and health monitoring.

• Digital twin and simulation integration: using modelling and digital twins to simulate, validate, and optimise in-orbit operations before deployment.

• Testing under relevant conditions: ground-based vacuum chambers, thermal cycling facilities, and robotic manipulators to replicate on-orbit environments.

Relevance to future space missions

In-orbit manufacturing and inspection technologies will extend satellite life, enable modular infrastructure, and reduce launch mass by allowing structures to be assembled and repaired in space. These capabilities are directly relevant to ISAM (In-Space Assembly and Manufacturing) initiatives and ESA’s and NASA’s long-term vision for sustainable space operations.

Collaboration invitation

TWI is seeking industrial and research partners to develop, test, and qualify in-orbit welding, coating, and NDT technologies. Our facilities support experimental validation, system integration, and technology transfer for space manufacturing and servicing applications.