Design and Fabrication Framework for Laboratory-Scale Test Specimens of Large-Scale Truss Structures Pertinent to Orbiting Solar Reflectors Utilizing 3D Printing and AssemblyMethods

Orbiting solar reflectors are envisioned as innovative tools to enhance clean energy production by directing sunlight onto solar power plants during dawn and dusk, thereby extending their operational hours. Construction of these large-scale mirrors in space presents unique challenges related to weight, strength, and structural integrity. Laboratory testing of these expansive structures presents considerable difficulties due to their sheer size. Scaling of the primary load-bearing truss members is performed to facilitate detailed mechanical analysis and performance evaluation. This approach ensures that critical structural characteristics are appropriately captured while optimizing for experimental feasibility. This article provides a comprehensive overview of the design, manufacturing processes, assembly techniques, and preparation of laboratory-scale test specimens for the principal truss components used in orbiting solar reflectors. The discussion includes considerations for material selection, geometric scaling, fabrication techniques such as fused deposition additive manufacturing and conventional manufacturing, and the methodologies that will be employed for the testing.