Turning Space Debris into Resources: The Space Debris Utilization Foundry (SDUF)

Earth’s orbit is becoming increasingly congested with defunct satellites, rocket bodies, and millions of fragments that pose risksto active missions and long-term space sustainability. Traditional debris removal concepts focus mainly on de-orbiting or destroying these objects, but this approach discards valuable materials already in space. The Space Debris Utilization Foundry (SDUF) presents a new pathway for capturing, processing, and repurposing orbital debris directly in orbit. By doing so, SDUF notonly mitigates a critical safety threat but also pioneers in-space manufacturing that reduces reliance on costly Earth launches. The concept is structured around a phased roadmap. First, a demonstrator in Low Earth Orbit (LEO) will prove debris capture, safe storage, and initial processing. Later, this system will evolve into a full orbital foundry capable of melting, reshaping, and 3D printing metals into useful components. The estimated cost for a demonstrator is between $80 million and $150 million USD, comparable to existing debris-removal missions, but with the added benefit of material recovery and reuse.