Roadmap for In-Space Manufacturing of Resilient Structures
Roadmap for In-Space Manufacturing
of Resilient Structures
Beckman Institute for Advanced Science and Technology
University of Illinois, Urbana-Champaign
May 19–20, 2026
Workshop Abstract
Space structures, vehicles and satellites have seen a steep rise in the last decade with numbers increasing at a staggering pace: the number of active satellites is projected to increase from 14,000 today to 60,000 by 2030. In addition to increased government initiatives, commercialization of the entire spectrum of space activities, ranging from launching services to deployment of large constellations of space structures has been a steady driver for economic and technological growth. The economic activity and cost to launch large numbers of space vehicles and structures make a strong case for developing robust capabilities for in-space servicing, assembly and manufacturing (ISAM).
Manufacturing for space and ISAM face major challenges that are not typical in manufacturing for ground-based structures, including supply chain, raw materials, transportation, energy demands, and environmental effects. Designing and manufacturing space structures must also account for a host of environmental threats that are not a consideration for Earth-based structures, including large temperature excursions, rapid erosion of polymer-matrix composites due to the combined effects of Atomic Oxygen (AO) and vacuum Ultraviolet (VUV) radiation, impact by Micro-Meteoroid and Orbital Debris (MMOD), etc.
The objective of this workshop on Roadmap for In-Space Manufacturing of Resilient Structures is to identify challenges and opportunities and generate a roadmap to develop resilient materials and structures for in-space assembly and manufacturing from the perspectives of fundamental and applied research. Integral to this roadmap is the development of partnerships between academia, government labs and industry to accelerate the deployment of new capabilities. Workshop speakers and participants will include researchers, program managers, and technology developers from academia, government labs (AFRL, NASA, etc.) and industry. The workshop will be structured around a small number of talks with ample time for discussions, focusing on the following topics:
Resilient Materials for In-Space Servicing, Assembly, and Manufacturing (ISAM)
Structures for Off-World Habitats and ISAM
In-Space Robotic Assembly
Characterization of Materials and Structures for Space Environments
System Integration and Industry Perspective
Workshop Agenda
Tuesday, May 19th
8:45 - 8:55: Introduction by Session Chair
Nancy Sottos, Materials Science and Engineering, University of Illinois Urbana-Champaign
8:55 - 9:20: The Orbital Manufacturing Initiative: Steps Towards an In-Space Factory
Jacob Rome, Senior Project Leader, Structures Department, The Aerospace Corporation
9:20 - 9:45: Rapid, Energy-Efficient In-Space Manufacturing of Composite Longerons
Sameh Tawfick, Mechanical Engineering, University of Illinois Urbana-Champaign
9:45 - 10:15: High-rate Manufacturing of Large Precision Space Structures
Harsh Bhundiya, Aerospace Engineering, University of Maryland
10:45 - 10:55: Introduction by Session Chair
Jeff Baur, Aerospace Engineering, University of Illinois Urbana-Champaign
10:55 - 11:20: Polymer Aerogel Materials for Off-World Exploration
Stephanie Vivod, Research Chemical Engineer, NASA Glenn Research Center
11:20 - 11:45: Expanding Space with Inflatable Softgoods
Douglas Litteken, Structural Engineer, NASA Johnson Space Center
11:45 - 12:15: Discussion led by Session Chair
13:30 - 13:40: Introduction by Session Chair
Xin Ning, Aerospace Engineering, University of Illinois Urbana-Champaign
13:40 - 14:05: From Rovers to Rafters: Translating NASA/JPL Robotics Experience to Resilient In-Space Servicing and Assembly
Philip Twu, Robotics POC for ISAM and technical group supervisor for Robotic V&V and Operations, Jet Propulsion Laboratory, NASA
14:05 - 14:30: Assembly of Large Space Structures with Stationary Robots
Sergio Pellegrino, Aerospace Engineering, California Institute of Technology
14:30 - 15:00: Discussion led by Session Chair
15:30 - 15:40: Introduction by Session Chair
Luke Baldwin, Air Force Research Laboratory
15:40 - 16:05: Space Weather Effects on Widegap Semiconductors and Polymers in Low Earth Orbit
Wolfgang Windl, Director of SPACEMAT Center of Excellence on Degradation of Materials in Low Earth Orbit, Materials Science and Engineering, The Ohio State University
16:05 - 16:30: Shields up! Transparent AO-Resistant Coatings and Systems for Orbital Applications
Kelly Chang, Lead Scientist, Orbital Applications, GE Aerospace Research
16:30 - 17:00: Discussion led by Session Chair
Wednesday, May 20th
8:45 - 8:55: Introduction by Session Chair
8:55 - 9:20: Starlab: Enabling Next Generation Materials Research and Manufacturing in Space
Jonathan Volk, Director for Advanced Materials Applications for Starlab Space, Voyager Technologies
9:20 - 9:45: Dcubed’s ARAQYS-D3 In-Space Manufacturing Demonstration Mission & Future Development Opportunities
Daniel Gillies, Chief Innovation Officer and Managing Director, Dcubed USA
9:45 - 10:15: Discussion led by Session Chair
Break-out Group Coordinators: Jeff Baur, Huck Beng Chew, Philippe Geubelle Aerospace Engineering, Nancy Sottos Materials Science and Engineering, Sameh Tawfick Mechanical Sciences and Engineering, University of Illinois Urbana-Champaign
Sponsored by:
THE GRAINGER COLLEGE OF ENGINEERING