In-orbit assembly of high-value modular infrastructures: Holistic analysis and mission concepts

Despite efforts to achieve a carbon-neutral economy by 2050, global dependency on fossil fuels is growing. Space-based power generation and transmission offers a weather-independent and economically feasible solution to enhance reliability and reduce costs. There is growing interest in testing and commercializing continent-scale Space-Based Solar Power (SBSP) generation and transmission. However, the orbital infrastructure deployment and associated logistics of a Solar Power Satellite (SPS) remain immature. Advancements in Robotics, Automation, and AI are key to enabling in-orbit assembly and operations for large infrastructures like SBSP and Large Aperture Space Telescopes (LAST). Addressing these challenges, the paper begins with a holistic cost–benefit and risk assessment of SBSP, structured around the Political, Economic, Social, Technological, Legal, and Environmental (PESTLE) framework. The paper further explores the significance of developing modular truss structures for in-orbit assembly and disassembly with robotic intervention, introducing an innovative tri-truss design that is both scalable and suitable for infrastructures such as SBSP and LAST. The paper showcases the scalability and versatility of the state-of-the-art End-Over-End Walking Manipulator (E-Walker) for undertaking in-orbit robotic assembly and disassembly of large infrastructures. Results from microgravity simulations using ROS2/Isaac Sim highlight E-Walker’s mobility performance and its potential to support expansive missions like SBSP and LAST. The Mission Concept of Operations outlines the assembly of a 25 m LAST mirror and defines a modular assembly and disassembly algorithm for a 2.5 m SBSP truss segment. By enabling collaborative in-space construction, E-Walker reduces the need for extravehicular activities and facilitates maintenance, manufacturing, and decommissioning. Collectively, this research advances the state of the art in in-space assembly technologies for future orbital infrastructure. • End-Over-End Walking Manipulator for autonomous in-orbit assembly and disassembly. • Mission ConOps for truss assembly of space telescopes and solar power satellites. • Validates E-Walker’s feasibility for orbital modular construction using ROS2/Isaac Sim. • Holistic Feasibility Analysis to assess the viability and long-term impact of SBSP. • Modular robotic systems to enable sustainable space infrastructure development.