Systems and methods for autonomous in-SITU resource utilization, processing, manufacturing and recycling

Abstract

Provided herein are systems and methods for autonomous in-situ resource utilization (ISRU), processing, manufacturing and recycling in space, including a factory system. The factory system may include: a factory comprising a preprocessing module configured to receive, classify, and sort input materials, a storage module configured to receive preprocessed input materials from the preprocessing module, a material processing module configured to receive preprocessed input materials from the preprocessing module and the storage module to undergo a transformation into a processed material to be used as part of a space system wherein the storage module is further configured to receive processed material from the material processing module, and an autonomous assembly module configured to receive processed material from at least one of the material processing module and the storage module and to assembly at least one of a space system and components of a space system.

Description

SYSTEMS AND METHODS FOR AUTONOMOUS IN-SITU RESOURCE UTILIZATION, PROCESSING, MANUFACTURING AND RECYCLINGTechnical Field

[0001] The embodiments disclosed herein relate to photovoltaic and wireless power transmission technologies, and, in particular to systems, apparatus, and methods for solar power satellite architecture in space exploration and development.Introduction

[0002] With global energy demand rapidly increasing due to population growth, industrialization of developing nations, rising living standards, and phasing out and diminishing economically viable sources of fossil fuels by the end of upcoming decades, new sources of clean, in particular non CO2 generating, energy generation for baseload capacity are needed. Space-based solar power (SBSP) offers a promising solution to pressing global challenges, especially within the context of sustainability and energy demand, enabling decarbonizing the energy sector in the coming decades. SBSP offers an abundant, continuous, and clean source of energy free of constraints of weather conditions or day-night cycle, and has the potential to significantly reduce global carbon emissions while providing an environmentally sustainable energy source for providing baseload power.

[0003] In the past, several solar power concepts have been proposed to use the Moon to implement production of space-based solar power devices. One proposed lunar power system was to use lunar power bases on eastern and western edges of the moon as viewed form earth, and another to use lunar-based SPS with in situ resource utilization of regolith from the Moon to reduce the amount of materials launched from earth. However, none of these concepts provide a solution for providing power for processing the regolith into the necessary building materials to the component mixture required. Therefore, there is a need in the art for systems which provide the initial power to enable in-situ resource utilization of space resources.Summary

[0004] Provided herein may be a factory system for manufacturing and recycling space systems in space, including of a factory comprising a preprocessing module configured to receive input materials, classify the input materials, and sort the input materials by classification, a storage module configured to receive preprocessed input materials from the preprocessing module, a material processing module configured to receive preprocessed input materials from the preprocessing module and the storage module to undergo a transformation into a processed material to be used as part of a space system, wherein the storage module may be further configured to receive processed material from the material processing module; and anautonomous assembly module configured to receive processed material from at least one of the material processing module and the storage module and to assembly at least one of a space system and components of a space system.

[0005] The factory may be on the Moon, in Earth Orbit and or in a Cis-Lunar orbit.

[0006] The space system may be a solar power satellite (SPS).

[0007] The space system is the factory and the autonomous assembly module assembles components for the factory.

[0008] The input materials may include at least one of: lunar regolith, lunar infrastructure, end- of-life solar power satellites, end-of-life space system components, space debris, and space resources.

[0009] The preprocessing module may include systems to cut, crush and / or grind input materials into particles and / or powders.

[0010] The preprocessing module may include at least one submodule from at least one of: magnetics separators, electrostatic separators, and filters.

[0011] The material processing module may perform at least one of: carbo-thermal methods, molten-regolith electrolysis, FFC Cambridge method, vapor phase pyrolysis, solar smelting, and water electrolysis.

[0012] The material processing module may generate at least one of: high-purity metals, oxides, oxygen, ceramic, glass, semiconductors, polymers, and alloys.

[0013] The autonomous assembly module may include robotic systems.

[0014] The autonomous assembly module may perform automated quality control and testing.

[0015] The autonomous assembly module may use artificial intelligence (Al) system and sensors to control and monitor the assembly of space systems and components.

[0016] The system may further include a recycling module configured to receive end-of-life input materials and to process the end-of-life input materials to base components to be used in a new space system.

[0017] The material processing module may receive base components from the recycling module.

[0018] The system may further include an additive manufacturing module configured to receive preprocessed materials from the preprocessing module and to create components from the preprocessing materials by additive manufacturing.

[0019] The materials for additive manufacturing may include at least one of a metal including silicon, aluminum, iron, calcium, magnesium and titanium, and a metal oxide including SO2, AI2SO2, TiO2, MgO, CaO, FeO, Na2O, K2O, P2O2, Cr2O3, MnO.

[0020] The system may further include a transportation network which transports space systems and space system components from the factory into orbit and from orbit to the factory.

[0021] The transportation network may include lunar landers to transport materials on the Moon.

[0022] The transportation network may include space tugs configured to carry materials, space debris, recyclable materials, and customer payloads to the moon.

[0023] The system may further include propellant depots in-orbit.

[0024] The system may further include an in-orbit assembly system to receive space components and to assembly space systems from the space components.

[0025] The system may further include autonomous robots for transportation of materials between modules and launching pads.

[0026] The system may further include autonomous robots configured to perform tasks including welding, cutting, and electrical integration.

[0027] The system may further include a plurality of ancillary services systems including at least one of power systems for providing power to the factory, resource extraction systems for extracting resources, command and control systems for controlling the factory, maintenance systems for monitoring and maintaining the factory, and a digital twin system located on Earth which provides a digital record of the factory for monitoring the factory in near real-time.

[0028] The digital twin system may enable simulation of a virtual environment for testing operational processes of the factory system.

[0029] The factory may replicate new environmentally adaptive systems configured to learn from operation data to improve efficiency, yield, and energy utilization in material processing, additive manufacturing, and assembly operation over time.

[0030] The factory may include an Al-driven control system utilizing reinforcement learning to optimize task scheduling, resource allocation, and replication sequences based on feedback from prior production cycles.

[0031] The Al-driven control system may update process parameters, such as temperature, feed rate, or additive manufacturing scan patterns, based on real-time monitoring and historical performance data.

[0032] The Al-driven control system may employ predictive modeling to anticipate maintenance needs, material shortages, or process failures and adjusts operations proactively.

[0033] Learning may be applied to the design of new components, structures, or factory modules, enabling the system to generate improved geometries, material combinations, or assembly methods for future production.

[0034] Multiple self-replicating factories may share learned operational data in a federated learning framework to collectively improve efficiency, replication fidelity, and output quality.

[0035] The Al-driven system may continuously adapt a Mine-to-Waste processing chain, including recycling strategies and material routing, to optimize yield and minimize waste based on prior processing outcomes.

[0036] Learning algorithms may evaluate environmental conditions, such as solar flux, radiation, or microgravity effects, and modify operational strategies to maintain consistent performance and system integrity.

[0037] The additive manufacturing module may be adapted to fabricate radiation shielding elements comprising sintered regolith blocks.

[0038] The system may further include a robotic assembly module configured to assemble fabricated structural parts into modular lunar infrastructure selected from the group consisting of landing pads, roads, habitat foundations, and mass driver components.

[0039] The system may further include a factory control module to implement a replication orchestration routine that dynamically allocates factory output between production of externally deliverable space systems and production of components for self-replication according to an energy-based priority metric.

[0040] The system may further include a powdered metal production module configured to atomize refined melts into metal powder having a controlled particle size distribution suitable for additive manufacturing.

[0041] Provided herein is a method for producing space system components in space, the method comprising producing products such as metals, metal oxides, oxides, composites, and alloys, recovered from space resources, using additive manufacturing to produce structural members and modular component frames from the recovered products, integrating printed structural members with electronics and fluidic subsystems in a robotic assembly to form replaceable spacecraft components, and performing non-destructive evaluation and functional testing of the formed replaceable spacecraft components prior to storage or transfer.

[0042] The method may further include producing products comprises extracting metals and volatiles from regolith, asteroid material, or recycled spacecraft components.

[0043] Additive manufacturing may include at least one of the following: microwave sintering, selective laser sintering, directed energy deposition, or binder-assisted printing.

[0044] The method may further include sintering printed components using thermal, microwave, or solar-concentrated energy to increase density and mechanical strength.

[0045] Robotic assembly may employ swarm coordination, Al-driven manipulators, and visionbased alignment for component integration.

[0046] The method may further include monitoring all production and assembly steps with Al- based process optimization and predictive maintenance systems.

[0047] The method may produce at least one of the following: solar power satellites, space architecture, propulsion stages, structural trusses, radiation shielding elements, space infrastructure on the moon,

[0048] The method may further include storing the tested spacecraft components in thermally regulated, vacuum-compatible containers for later deployment.

[0049] The method may be performed by a self-replicating factory capable of producing additional factory modules autonomously using recovered space resources.

[0050] The method may further include continuously learning from production and testing data to adapt fabrication parameters and improve yield, quality, and energy efficiency.

[0051] Other aspects and features will become apparent to those ordinarily skilled in the art, upon review of the following description of some exemplary embodiments.Brief Description of the Drawings

[0052] The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification. In the drawings:

[0053] FIG. 1 is a diagram of a solar powered satellite (SPS) architecture of operations system, shown in space, according to one embodiment;

[0054] FIG. 2 is a diagram of an architecture of operations in space, according to an embodiment;

[0055] FIG. 3 is a block diagram of the common architecture elements for a META-LUNA manufacturing system, and the components required for a self-replicating factory, according to an embodiment;

[0056] FIG. 4 is a pie chart of multi-criteria decision analysis (MCDA) critical impact categories for META-PRIME, according to an embodiment;

[0057] FIG. 5 is a pie chart of MCDA critical impact categories for META-LUNA, according to an embodiment;

[0058] FIG. 6 is a bar graph of weighted impact categories following MCDA for META-PRIME and META-LUNA, according to an embodiment;

[0059] FIG. 7 is a diagram of the components of three meta-platforms, META-PRIME, METALUNA, and META-ALCHEMIST, in space, according to an embodiment

[0060] FIG. 8 is a diagram of the circularity of the three meta-platforms, META-PRIME, METALUNA, and META-ALCHEMIST, according to an embodiment; and

[0061] FIG. 9 is a flow diagram of a method of manufacturing components or systems through a META-LUNA factory, according to an embodiment.Detailed Description

[0062] Various apparatuses or processes will be described below to provide an example of each claimed embodiment. No embodiment described below limits any claimed embodiment and any claimed embodiment may cover processes or apparatuses that differ from those described below. The claimed embodiments are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below.

[0063] The systems and methods herein employ recent advancements in thermophovoltaics (TPV), photovoltaic and wireless power transmission technologies to enable the collection of solar energy in the sunlit regions of space without the constraints of atmospheric interference or day night limitations, to deliver clean, abundant, affordable, and secure energy. Combined with the use of regolith a sustainable approach to space-based energy harvesting is provided, addressingthe needs of in-space manufacturing, with the aim of continually reducing the reliance on Earth- launched resources, decreasing launch costs, and minimizing the environmental impact associated with traditional space missions.

[0064] Herein are provided three different systems for power generation in space, including i) META-LUNA, a self-replicating modular lunar factory for converting regolith, manufacturing components as well as recycling SPS, ii) META-PRIME, a system of SPS production and construction deployed to LEO and assembled in GEO, which deliver power to Earth and to Space based industry, and iii) META-ALCHEMIST, an in-orbit manufacturing and recycling facility with autonomous servicing robots for reusing and repurposing materials, and facilitating and extending end-of-life of SPS components. These systems are separate but work together as part of the “Multi-domain Operations using Rapidly-Responsive Phased Energy Universally Synchronized” system or to provide sustainable alternative energy source to Earth and Space. The system is described in detail below.

[0065] 1 .1 Solar Power Satellites

[0066] Space-based solar power (SBSP) harvests solar radiation via orbiting power plants in space which capture solar energy and use it in construction, production and operation as well as convert it to electromagnetic radiation which is then transmitted wirelessly to ground and space based receiving stations, including arrays of receivers. On Earth these receivers are connected into the electrical grids that run to homes, offices, factories, etc., meeting daily power needs on Earth. In space, receivers may be connected to space systems to charge batteries and other storage devices.

[0067] Solar Power Satellite Architecture

[0068] Herein a novel approach for designing and building solar power satellites using sustainability principles to achieve greater resilience, reduce environmental impact and increase economic value is presented.

[0069] The system is an SPS architecture that is designed using sustainability principles, optimized using Life Cycle Assessment (LCA) and eco-design principles to minimize the environmental footprint. LCA is a systematic method used to evaluate environmental impacts across the life cycle of the system from design through to end-of-life (EoL) management. Eco- design is an approach used to design products with the goal of reducing the environmental impacts throughout the entire life cycle, while maintaining or improving the products’ functionality, quality, and economic viability. To do this, LCA can be integrated as a mission driver of the space mission design process offering substantial advantages in the design of solar power satellites, allowing for environmental impacts of the SPS to be monitored continuously, enabling stakeholders and key decision-makers to gain an in-depth understanding of where the hotspots are in the life cycle, and most importantly provides an opportunity to address them before the design becomes locked-in.An example of a sandwich type solar power satellite which may be used in the architecture is shown in Figure 1 . The SPS include a sandwich of solar cells on top (i.e., the sun facing side) and microwave elements on the bottom (i.e., the Earth-facing side). Reflectors capture the solar radiation and direct it to the solar cells. Both the reflectors and the SPSs exist in swarms which are synchronized both as solar cells and SPSs and together. The SPS receive the solar radiation, convert the radiation to microwave energy, and send the microwave energy to Earth to a plurality receiving stations comprising arrays of rectifying antennas or “rectennas”. This system is the first SPS that is designed using sustainability principles. The platform features modular, distributed systems, made of lightweight, inflatable and deployable kinematic structures, which can autonomously assemble, with robust command and control. Large structures can be created by combining many smaller units, enabling a scalable platform for dispatchable power. The system is composed of two types of satellites, the Metasat reflector and Metasat sandwich. These are independently operating and are synchronized to each other and controlled relative to each other. They are modular in design, with distributed computed enabling multi-use systems. They are fully recyclable, reusable, and with recoverable materials. Furthermore, this SPS concept integrates products and systems for longevity, recyclability, and reduces the environmental impact while minimizing waste & maximizing resource efficiency, harmonizing the principles of sustainable design, the circular economy, and transition towards Net Zero. Sustainable design aims to meet the needs of the today without compromising the ability of future generations to meet their own needs. It involves considering the environmental, social, and economic aspects of a product or project throughout its lifecycle. Key fundamentals of sustainable design include using environmentally friendly materials, optimizing energy efficiency, reducing waste, and considering the well-being of communities and ecosystems affected by the design. The Circular Economy's emphasis on resource efficiency is synergistic with Net Zero targets by reducing emissions associated with resource extraction, production, and disposal. Conversely, the Net Zero transition necessitates a shift to cleaner and more sustainable energy sources, which can be facilitated by the Circular Economy's principles of energy efficiency and renewable energy integration, accelerating the transition towards more sustainable societies. This unique approach not only ensures limitless energy collection but also reduces the dependence on finite terrestrial resources, while minimizing the carbon footprint associated with terrestrial supply chains associated with the production of future solar power satellites, while facilitating seamlessly integration of sustainable practices into the engineering and optimization of life cycles, and accelerating the global transition towards a net- zero emissions future, be facilitated by the Circular Economy's principles of energy efficiency and renewable energy integration, accelerating the transition towards more sustainable societies. This unique approach not only ensures limitless energy collection but also reduces the dependence on finite terrestrial resources, while minimizing the carbon footprint associatedwith terrestrial supply chains. As well continual efficiency upgrades can be added as components evolve over time.

[0070] In other implementations, the Metasat Sandwich may be composed of multi-source TPV systems on one side and electromagnetic transceiver (e.g. microwave element and or lasers) on the other side to serve as transceiver to transmit power to other transceivers and or receivers on Earth and or in Space. The TPV system may use energy sources such as solar radiation and or combustion of fuel to generate heat a thermal emitter, which then radiates producing photovoltaic photons to pn junction cells for power generation. Additionally, filters and strategies for waste heat and photon recycling may be used to enhance utilization of specific wavelengths for maximum efficiency for conversion efficiency.

[0071] 1 .3 Manufacturing in Space and Solar Power Satellites

[0072] To further minimize the environmental footprint, the use of space resources was investigated with the goals of moving the majority of the manufacturing of an SPS to space.

[0073] The concept of utilizing space resources to build SPS was first proposed by Dr. Gerard O’Neill. In 1975, O’Neill proposed the construction SPS using lunar materials and then transporting them to Earth orbit, reducing the impact of transportation costs from the Earth. The raw materials from the Moon would be launched via electromagnetic launchers or mass drivers to a space manufacturing facility. O’Neill’s project envisioned the creation of large colonies or communities at gravitationally stable points in the Earth-Moon system (at the Earth-Moon L4 or L5 libration points) to provide labor for building further such structures and SPS on an ongoing economically driven basis. In 1980, with rising launch costs of NASA’s space shuttle program, O’Neill et al. explored options to minimize research and development costs and developmental risks. Three potential scenarios were considered: Scenario 1) Partially self-replication system, with industrial operations only on the lunar surface; Scenario 2) Totally automated lunar-based system; and Scenario 3) Partially self-replication system on Moon and in orbit, equipment on Moon used for replication of mass-drivers, equipment in space used for replication of wide range of components. It was concluded that scenario 3 offered the best option. However, lunar manufacturing of SPS would require building a base on the Moon and mass drivers to send material to a space manufacturing facility. Further studies were conducted into self-replication growing lunar factories in the subsequent years, but the development of autonomous drone and robotic technologies for self-replicating construction has considerably updated the capabilities of this model while the need for sustainable energy has increased rapidly and shifted the focus of such operations.

[0074] 2.0 STATE OF THE ART

[0075] 2.1 Lunar SPS Concepts

[0076] Several Solar Power Satellite concepts have been proposed offering a different approach to utilizing the Moon to implement space-based solar power. They can be separated into two category types - the first type transforms the Moon into a power generation anddistribution station, where solar collectors are placed on the lunar surface, solar energy is converted to microwave or laser energy and transmitted to receiving stations on Earth, and the second type utilizes the resources of the Moon to build solar power satellites.

[0077] The first type, Lunar Power System was described by Mueller in 1984 and developed in detail by Waldon and Criswell in 1985. Further development of this concept lead to the use of orbital reflectors / retransmitters, to send low intensity microwave power to rectennas on Earth. Criswell has further expanded on this concept as described in several subsequent publications. The Lunar Power Station would include lunar power bases on the Eastern and Western edges of the Moon as viewed from the Earth, delivering 20 terawatts of received power. In 2009, the Shimizu Corporation proposed the “Luna Ring,” including developing a 400 km wide ring of photovoltaics around the lunar equator to continuously transmit microwave and laser power to receivers on Earth, the system would be capable of transmitting 13,000 terawatts.

[0078] The second type are lunar-based SPS with architectures that use in situ resource utilization and the Moon to reduce the amount of materials launched from the Earth. NASA supported several studies to leverage the Moon to build SPS, in 1979, General Dynamics and MIT completed analysis of scenarios of utilizing the Moon to build the NASA / DOE Solar Power Satellite reference design. General Dynamics concluded that 90% of the mass of the SPS could be built using lunar material, and MIT concluded that 96% of the SPS mass could come from the Moon. In 1985, commissioned by the Space Studies Institute, the Space Research Associates designed a solar power satellite that optimized the use of lunar material, and with over 99% of materials used in construction of the SPS being from lunar materials.

[0079] In 2015, Schubert et. al. introduced, the Tin-Can SPS, an open cylindrical shell approximately 6.4 kilometers in both diameter and height, with the wireless power transmission module 1 km in diameter, the architecture components would be sourced from the Earth and the Moon. Additionally, the design assumed an existing cislunar infrastructure to move materials electromagnetically, and a large-scale manufacturing capability which operated robotically, powered by sunlight that can provide: solar panels made of single crystal are single crystal silicon with a silicon dioxide protective and anti-reflective layer; iron for the shell surface, which are fabricated in orbit from the spherical payload canisters carrying the lunar sourced PV, they are extruded from a solar-powered smelter, T-shaped beams are formed, cut to length and welded together, iron would also be used for the fasteners that linked the framed to house the PV, manufactured by extrusion in zero-gravity; and aluminum sourced from the Moon used for making electrical connections with the frames, slotted waveguides, and aluminum wire for transport of DC power to the central spite. Electrical components too complex for the factory to manufacture would be sourced from Earth (e.g. amplifiers, polymer wires, transformer-converter units).

[0080] In 2016, Lewis-Weber, proposed the development of a Lunar-Based Self-Replicating Solar factory using the SPS Alpha architecture, where the space solar power components would be manufacturing on the Moon and then launched using mass drivers, the space solar powercomponents would self-assemble in geosynchronous orbit (GEO) and wirelessly transmit microwave energy to receivers on the Earth .

[0081] In 2022, Ellery explored the notion of constructing SPS from lunar resources and identified that two core components would be essential to SPS, the magnetron and the rotary joint which may be applicable to several SPS concepts. The magnetron may be constructed from lunar resources using a CaO-coated tungsten cathode, Ni control grid and anode, fused silica glass tube with elements of the electric motor. The rotary joint may be constructed using AINiCo alloy, ferrites, and kovar wiring respectively which can be sourced from lunar material. Applicable SPS concepts may include NASA Suntower SPS, European Space Agency Sail Tower SPS Concept, Multi- Rotary Joints Solar Power Satellite from Chinese Academy of Space Technology, Korea Aerospace Research Institute’s Korea Space Solar Power Satellite, and Thales Alenia Solar Array Matrix SPS Concept.

[0082] In 2023, Switzerland’s Astrostrom, proposed the Greater Earth Lunar Power Station concept which includes a habitable solar power satellite orbiting the Moon, a rectenna station on the lunar surface, surface mining, processing, and manufacturing, and a lunar surface-to-Earth Moon Lagrange point 1 transportation system (lunar space elevator). Raw materials (e.g. aluminum, oxygen, silica, and various other metal silicates, glasses and basalts, geopolymers (lunar polymers) components from lunar regolith would be processed into PV and structural elements, transported to orbit and assembled robotically in a lunar halo orbit at the Earth-Moon Lagrange point 1 (EM-L1). At EM-L1 , all of the manufactured components from the lunar surface would be assembled. The solar panels are based on iron pyrite monograin solar cells produced on the Moon, structural elements made from basalt fibres, rectennas on the Moon will be constructed using basalt and aluminum via robotic 3D printing manufacturing processes. Complex items such as microwave generators and amplifiers, and control computers that cannot be manufactured on the Moon will be shipped from Earth to a cargo hub at EM-L1 and integrated into the assembly process, additionally it is envisioned that fuel from the Earth may be transport to the Moon to support initial lunar Surface to Orbit operations, a cargo shuttle to transport materials between Earth and the Moon, towards the implementation of a lunar space elevator.

[0083] 2.2 LCA applied to lunar SPS Concepts

[0084] T o date, only a handful of LCA studies have been conducted on SBSP concepts. Wilson et al. (2024) provided the most up-to-date literature review into such studies, expanding on a review initially conducted by Wilson et al. (2020) and followed up by Oqab, et al. (2023). Wilson, et al. (2024) identified a total of eight LCA studies on SBSP which have taken place (including the case study of that paper). However, none of these studies have specifically addressed the environmental impacts of lunar-based SPS concepts.

[0085] Despite this, from these known studies, of relevance to this paper is the study of Oqab, et al. (2023), which publicly introduced the SPS concept for the first time. Given the evolution of this concept towards lunar-based applications (outlined further in Section 3), the environmentalimpact is relevant. In this regard, Oqab, et al. (2023) revealed that process-based LCAs had been run at the end of each design iteration using the Strathclyde Space Systems Database (SSSD). The SSSD is a space-specific LCA tool which was developed at the University of Strathclyde and is now maintained by Metasat. The tool was used to determine the environmental footprint of the system and guide the next design iteration in an effort to both improve the system and reduce adverse impacts as far as practically possible without compromising technical aspects. Based on this approach, it was revealed that when the system is fully deployed, it is capable of producing a carbon footprint of just 6.42 gCO2e / kWh - the lowest reported GHG footprint of an SPS concept to date (although the reported carbon footprints of all these studies are not directly comparable). From the latest analysis, climate change is relatively insignificant compared to ozone depletion or water use. In terms of ozone depletion, >99% of the impact comes from the launch event due to the release of aluminum oxide, black carbon and radical emissions. For water use, 62.25% of the impact from production of the rectennas and a further 16.77% from the production of the SPS units during the production & manufacturing of the aluminum and electronic components. This is primarily due to the large volume of distilled water which is used to spin turbines to produce electricity, and the amount of water used in cooling loops for the steam exiting the turbines. Regardless, the concept has been updated since to improve on this score.

[0086] Although the conventional concept for delivery of power to Earth (META-PRIME) provides promising results, due to the difference in application, there is a distinct need to recalculate the environmental impacts of the new META-LUNA concept to ensure that the technology is in-line with ongoing environmental footprint reduction efforts.

[0087] 3. META-LUNA CONCEPT

[0088] 3.1 Benefit of lunar manufacturing

[0089] Building solar power satellites using the Moon offers benefits for Earth and the future of space exploration. Some of the potential benefits associated with utilizing lunar resources include: (1) Lower energy requirements for delivery of materials from the Moon to GEO than Earth to GEO, resulting in reduced number of launches which in turn translates to major reductions in the emission and environmental impacts of launches and reducing transportation costs; (2) Increases in the efficiency of deploying SPS; (3) Establish a new supply chain for building SPS and reducing the depletion of resource of Earth; (4) The Moon's unique environment, with a near vacuum atmosphere, water, or weather disturbances, allows equipment and infrastructure to have a much longer operational life, free from the corrosion and wear experienced on Earth, this translates into lower maintenance costs and more durable technologies; (5) In addition, operating on the Moon presents reduced risks from major environmental catastrophes, such as earthquakes, floods, or other natural disasters, which could disrupt Earth-based manufacturing and supply chains. By shifting manufacturing of SPS to space, the risks associated with terrestrial disasters are avoided, ensuring a more stable and secure production process.

[0090] 3.2 Meta-Luna Overview - CONOPS

[0091] To further reduce the environmental footprint of the SPS on Earth, the utilization of the resources on the Moon is proposed. The META-LUNA concept aims to create a self-replicating modular lunar factory capable of autonomously producing Space Solar Power components, while also creating modules to expand manufacturing capacity overtime, sustaining the factory using lunar resources. Materials from the Earth are transported to the Moon to set up the initial components of the lunar factory. The lunar factory is envisioned to grow overtime by using not only the materials from the Moon, but also including recycling space solar power satellite, space debris, space systems at the end of life in space such as satellites and lunar infrastructure, and other space resources like solar wind, materials from Mars and asteroids.

[0092] Figure 2 provides an updated concept of operations for the SPS architecture.

[0093] 3.2 Common Architecture Elements

[0094] The META-LUNA concept includes a self-replicating modular lunar factory for manufacturing and recycling of space systems, and transportation network and autonomous robotics for logistics and construction of SPS. The lunar factory is designed as a modular system, where each module performs a specific function. The factory is envisioned to be self-replicating, where an initial set of modules are launched from Earth to serve as a seed to kick start manufacturing and production. As the need to produce more SPS or other products increase, the factory can produce more modules and scale to expand production capabilities over time to meet demand. The factory output can match the implementation and decommissioning plans of SPS architectures. The modular design would also ensure that parts and machinery can be replaced or upgraded, the interchangeable parts also allow for easy repair and maintenance, to reduce down time for continuous operations. The concept involves integrating various technologies such as autonomous robotics, artificial intelligence (Al), materials extraction, processing, and additive manufacturing (3D printing) for fabrication of SPS, and to make the factory capable of replicating all the necessary components and machines to reproduce itself. Powered by sustainable energy sources like electricity generated by solar power satellites in lunar orbit and solar power, the factory would extract raw materials from the Moon, manufacture its own parts, and assemble new factory modules. The lunar factory fully automated construction of solar power satellites (SPS), leveraging robotics and advanced manufacturing techniques to build and assemble complex structures without human intervention. It is envisioned that the lunar factory would have increasing levels of autonomy, with the goal of reducing human involvement to remote monitoring, with the factory capable of managing most or all operations independently. The system would also develop magnetic and other protection for the factories from the harsh environment, paving the way for future human integration. The factory would incorporate Al driven processes with learning capabilities

[0095] Figure 3 provides an overview of the common architecture elements for a META-LUNA system 300 and the components required for a self-replicating factory.

[0096] Figure 3 includes a lunar factory 305 which receives inputs 310 into a pre-processing module 320. The inputs 310 may include lunar regolith, lunar infrastructure, end-of-life SPS and other space systems, space debris, and other space resources. The pre-processing module 320 pre-processes the inputs 310 and they are sent to at least one of a material processing module 322, a recycling module 324, an additive manufacturing module 326, and a storage module 328. The modules may then send outputs to an autonomous assembly module 330.

[0097] The autonomous assembly module 330 send outputs to a logistics and construction system 340 including a transportation network 342, autonomous robots 344, and an in-orbit assembly system 346.

[0098] The outputs 350 of the logistics and construction system 340 includes solar power satellites (SPS), new space systems and components, propellants, metals and alloys, water, etc.

[0099] Ancillary services 360 provide functionalities including power, resource extraction, command and control, maintenance, and a digital twin. The digital twin is a computer system on Earth which provides a record in near real-time of the functioning and status of every component of the META-LUNA system.

[0100] The various components are discussed in more detail below.

[0101] 3.2.1 Inputs 310

[0102] Feedstock for the factory will include lunar regolith, solar power satellites or space system components at the end of life, space debris captured and transported to a processing site, lunar infrastructure, other space resources (e.g., Mars or asteroidal materials) and waste products from the increasing human activity on the Moon.

[0103] 3.2.2 Pre-processing module 320

[0104] Pre-processing modules sort input feedstock. This involves classifying materials by size, density, and composition (for example separating metals, metal oxides, silicates, and volatiles). Automated Al-driven sensor-based sorting systems would identify different material types for optimized processing methods. Before refining, large materials of lunar regolith would need to be broken down into smaller, manageable sizes. The pre-processing module would include systems to crush and grind these materials into fine particles or powders. The separator sub-modules would include: 1) magnetic separators to pull out valuable ferrous materials for further refinement. 2) electrostatic separators could be used to further separate materials based on their charge properties. Additionally, subsystems using electromagnetic radiation for dewatering and drying may be implemented to remove excess water from feedstock, especially from lunar regolith.

[0105] Herein the modules are described in plural, however, there may only be one module of certain types of modules in a given lunar factory system.

[0106] 3.2.3 Material Processing Module 322

[0107] Materials from the pre-processing modules undergo transformations in material processing modules using in-situ resources processing methodologies such as: carbo-thermal methods, molten-regolith electrolysis, FFC Cambridge Method, Vapor Phase Pyrolysis, SolarSmelting, Water Electrolysis to create high-purity metals, ceramics, oxygen, ceramic, glass, semiconductors, polymers, alloys or maintaining and replicating the lunar factory itself.

[0108] 3.2.4 Additive Manufacturing Module 324

[0109] Additive manufacturing modules are responsible for fabricating a wide variety of parts, tools, and structures directly from raw materials. Regolith-based additive manufacturing or 3D printing can be used to produce structures and machinery parts. Sintering of regolith using induction systems, where the material is heated to bond without fully melting, can be utilized to build durable components like the factory walls, structural components, and equipment housings. Manufacturing of a range of equipment, satellite components, propulsion systems can be developed using lunar-derived metals (e.g., silicon, aluminum, iron, calcium, magnesium and titanium) and metal-oxides (SO2, AI2SO2, TiO2, MgO, CaO, FeO, Na2O, K2O, P2O2, Cr2O3, MnO). Other sintering techniques may include RF Sintering, concentrated solar, laser sintering. Additive Manufacturing or 3D Printing technologies can be used for on-demand manufacturing of robotic systems, satellite components, factory parts and tools could be derived directly from metal powders extracted from lunar soil, or metals created via processing of feedstock. Using 3D printing techniques (e.g. microwave sintering, laser sintering and electron beam melting etc.), would produce the key components necessary to construct SPS. The sandwich structure, with one side solar cells made of silicone, and the other side made of microwave elements would be printed using thin-film materials or composites derived from lunar resources. Aluminum would be used for the supporting structures as well as the reflectors. Initially, complex items such as elements for the phased array transceivers, electronics, amplifiers, and computer systems that cannot be manufactured on the Moon will be shipped from Earth, but over time these materials will built using lunar regolith and recycled materials from other space systems that are processed by the lunar factory.

[0110] 3.2.5 Recycling Module 326

[0111] Recycling modules are designed to process and repurpose waste materials, defective parts, and space systems components at the end of their life. Its primary function would be to ensure a closed-loop system that minimizes waste and maximizes resource efficiency, which is essential for sustained operations in the resource-scarce environment of the Moon. Similar to production processes, the materials processing module would also handle the recycling of materials from solar power satellites at the end of life, space debris, failed or decommissioned components. Metals, ceramics, and silicon can be melted down and reused, while other waste materials could be processed and reintegrated into the production loop. This would include space debris from Earth orbit or Cis-lunar space which may be transported to the lunar factory to be processed and repurposed. The factory would employ systems to recycle and reuse materials from obsolete equipment, failed parts, and even waste from the manufacturing processes. The SPS is designed to be fully recyclable, reusable and incorporates recoverable materials. Each satellite module is easily assembled and disassembled. Recycling modules would break downmaterials to their base components, which are then reprocessed and reused in the factory to build new SPS components or replicate a component of the factory.

[0112] 3.2.6 Storage Modules 328

[0113] Storage modules are configured for storing processed materials, different propellants for later use, pressurized tanks for volatiles and gas storage, and temperature-controlled storage for transportation. Storage modules in the form of a battery may also be incorporated into the design.

[0114] 3.2.7 Autonomous Assembly Module 330

[0115] Autonomous assembly modules integrate the parts produced by the materials processing additive manufacturing modules, recycling modules, and storage modules, transforming them into fully operational components of the solar power satellites, the Metasat Sandwich and Metasat Reflectors would be ready for deployment and assembly in space. Robotic arms would assemble the additively manufactured satellite components. This module would also include automated quality control and testing with automated quality control tests on each part such as vibration testing, thermal stress tests, and radiation shielding tests. Sensors and Al systems would detect and correct any issues, such as misalignments, weak connections, or malfunctioning components. The assembly module would operate in a flexible, on-demand manner, adjusting production schedules based on resource availability, energy conditions, or operational needs. For instance, it could prioritize building smaller satellite components when resources are limited, or focus on larger components, more complex assemblies when sufficient materials are available.

[0116] 3.2.8 T ransportation Network 342

[0117] A transportation network include the infrastructure for transportation from the lunar surface to Earth orbit. Fully assembled SPS modules are transported via space tugs and reusable lunar landers. Materials are transported from the lunar surface to lunar orbit to rendezvous with the space tugs acting as cyclers, which would ferry them from Lunar Orbits to Earth Orbits. Afterwards, the cyclers would carry materials, space debris, recyclable materials, and customer payloads to the Moon. The propellant to power the network would be manufactured using the lunar factory and or from recycled materials. Propulsion systems would be additively manufactured, and combustion profiles would be calculated with propulsion systems calibrated to the specific use case. Additionally, propellant depots may be built in lunar orbits and Earth orbits to support the transportation network, where cyclers would refuel in orbit, to transport materials to the desired SPS location for example GEO, and or transport SPS at the end of life or decommissioning phase, or other materials to the lunar factory to be recycled. Furthermore, these propellant depots can support other space activities for commercial operations. Other configurations for transporting materials from the Moon may include electromagnetic launchers or mass launchers or lunar elevators to orbit combined with space tugs, or a hybrid configuration of lunar landers, mass drivers, and lunar elevators, in combination with cyclers and space tugs.

[0118] 3.2.9 Autonomous Robotics 344

[0119] Autonomous robotics may be integrated into the lunar factory for manufacturing solar power satellites, thereby enabling efficient, continuous, and precise production without the need for human oversight. The autonomous robots may include autonomous rovers that can transport materials between mine sites, processing plants, and launching pads. The autonomous robots may be Al-driven and wirelessly powered to operate independently on the Moon’s surface. The autonomous robots may handle anything from material transport, component fabrication, to assembly, optimizing resource use and minimizing waste. The autonomous robots may be equipped with Al-driven control systems and robotic arms allow for precision tasks such as welding, cutting, and electrical integration, while adaptive systems enable on-the-fly adjustments to production demands. Additionally, the autonomous robots may be equipped with selfdiagnostic capabilities for real-time maintenance and repair, ensuring uninterrupted operations and are networked so they learn from each other and optimize overall processes. With the ability to perform complex assembly quality control tasks, and learn over time, utilizing autonomous robotics would enable the lunar factory to produce highly efficient and scalable systems for selfreplication, that would be capable of support the manufacturing of satellites tailored to mission requirements of producing new SPS while optimizing for end-of-life operation of the overall architecture with the use of lunar resources effectively.

[0120] 3.2.10 In-Orbit Assembly & Disassembly 346

[0121] Autonomous Al-powered robotics play a crucial role in assembling and deploying SPS in space with the architecture. Once satellite components are manufactured and sent from the lunar factory, in-orbit servicing robots manage the logistics of the self-assembly of the reflector arrays, structural frames, and sandwich panel. The service robots are equipped with zero-gravity manipulation tools and Al-driven precision command and control, which can autonomously cut, weld, bolt, and secure SPS components in space, in the case issues may arise in the operation of independent satellites. They ensure the smooth self-assembly, deployment of kinetic and inflatable structures, preparing them for operational energy collection and transmission. Additionally, in-orbit servicing robots can perform maintenance tasks and repairs, extending the lifespan of SPS components already in service. This autonomous approach reduces the need for humans to manage logics, leading to increased safety, and allows for the rapid construction and deconstruction of entire sections of solar power stations, on an as needed basis. New tasks can also be performed and learned in a virtual environment to streamline operations.

[0122] 3.2.11 Outputs 350

[0123] META-LUNA 300 may output SPSs, new space systems and components, propellant, metals and alloys, and water, amongst other components. The self-replicating factory produces a wide range of outputs, including spacecraft and replaceable system components such as structural members including tubular trusses, node intersections, and panels, fabricated by additive manufacturing using Mg-, Al- or Ti-based alloys produced on-site, beams, brackets, andpanel frames with standardized mechanical interfaces constructed in low gravity for the use in space giving them a lighter weight and longer spans not possible to be produced on earth, thermal management hardware such as radiators with metal fin arrays, heat pipes with metallic sintered wicks, deployable concentrator frames, RF and optical mounting fixtures, phased-array support structures fabricated as modular tiles for robotic assembly, and reaction control hardware including tanks, valves, and piping for pressurized propellant handling tested to specified pressure ratings; propellant and oxidizers including oxygen produced via molten regolith electrolysis or chemical reduction and stored as cryogenic liquid oxygen or high-pressure gas, hydrogen obtained by electrolysis of captured water for direct or liquefied use in high-lsp propulsion or bipropellant systems, and methane or other hydrocarbons produced when imported carbon is available for methane-LOX propulsion, all subject to contaminant concentration, cryogenic boil- off, and material compatibility tests; metals and alloys including metallic powders produced by atomization of refined melts with controlled particle size distributions for additive manufacturing, alloyed to produce specified compositions such as Al-Si or Fe-Ti, and verified for mechanical properties including tensile strength, yield, elongation, and porosity; water and other volatiles extracted via thermal desorption from regolith under vacuum followed by cold-trap condensation and fractional distillation, stored in thermally insulated tanks optionally covered by regolith, and purified through multi-stage processes for potable, electrolysis, or coolant use; lunar infrastructure such as roadbeds, landing pads, foundations produced via regolith compaction, microwave sintering of surface layers, and additive or cast load-bearing blocks, mass driver base components and rails fabricated from precision metallic segments joined by welding and alignment, and habitat shells formed by additive printing of sintered regolith or cast glass domes reinforced with metallic frames; and radiation shielding elements including modular panels composed of metal tanks with water cores and outer regolith casing that interlock to form continuous walls, berms and overburdens created by automated excavation to form below-ground habitats with controlled regolith depth, and layered shielding configurations balancing mass per unit area and radiation attenuation performance, with hydrogen content optimized for galactic cosmic ray moderation and high-Z materials mitigating secondary neutrons and bremsstrahlung. Using the outputs, the self-replicating factory autonomously performs processes that produce spacecraft and replaceable system components, propellant and oxidizers, metals, metal oxides and alloys for structural and additive manufacturing applications, water and hydrogen / oxygen feedstocks, modular lunar infrastructure such as habitats, landing pads, and roads, and radiation shielding elements for construction and habitat protection, while simultaneously allocating resources to fabricate additional factory modules for self-replication.

[0124] 3.2.12 Ancillary Services 360

[0125] META-LUNA 300 is supported by ancillary services 360 such as power services (initially, although the factory may become self-supporting for power at some point), resource extraction (e.g., mining of regolith), command and control (e.g., computer systems for controlling thecomponents individually and collectively), maintenance (e.g., monitoring statuses and providing maintenance when necessary), and digital twin. The digital twin of the factory is created to enable continuous management and supervision of operations, with logistics and maintenance schedules adhered to optimize operation and maximize production. Additionally new operational processes can be simulated in a virtual environment to ensure continuous performance. The virtual environment can also serve as a testing ground for new algorithms for expanding processing, manufacturing, and recycling operations.

[0126] 3.3 Environmental modelling of META-LUNA

[0127] Environmental modeling of the META-LUNA lunar factory for assembling SPS was performed. LCA results for META-LUNA were calculated over a 30-year time period for twenty- five full-scale SPS systems capable of generating 2 gigawatts (GW) of power to the lunar surface, and mirroring the system boundary of META-PRIME. The modeling assumed an average lifetime of thirty years for each SPS, incorporating replacement of components due to maintenance and rapid response events. The Falcon Heavy was used as a launcher for transporting the initial equipment needed to a lunar base. An assumption was used that 50% of the materials required to build the rectennas and SPS units were produced by the lunar factory, as a conservative estimate. The life cycle inventory (LCI) was modelled using Strathclyde Space Systems Database (SSSD) v1.0.3, with the life cycle impact assessment (LCIA) phase using new impact categories based on the European Commission’s Environmental Footprint (EF) approach. As such, the results are not comparable to the previous SPS LCA studies outlined above in section 2.2.

[0128] Overall, results were collected across a total of 29 midpoint environmental impact categories defined by the SSSD, based on the EF recommended impact categories and ESA LCA Handbook, as recommended by Wilson et al. (2021). To determine the most critical impact categories to address, multi-criteria decision analysis (MCDA) was applied. The MCDA results for META-PRIME and META-LUNA are shown in Figures 4 and 5, respectively. MCDA can be used in decision-making to address multidimensional results and reach conclusions. To do this, firstly the results were normalized according to the annual consumption of an average global citizen, which is based on JRC guidance issued by the European Commission. They were then weighted according to the perceived relative importance of each impact category (meta-weighting), which is also based on JRC guidance issued by the European Commission. This approach then allowed the severity of 16 impact categories to be gauged. A comparison of the severity of the impact of META-PRIME and META-LUNA in the 16 impact categories is shown in Figure 6.

[0129] 4. ENVIRONMENTAL IMPACT

[0130] 4.1 LCA study

[0131] From the comparison in the above noted LCA study, there was an average reduction in environmental impacts of 37.48% across all indicators. There was no significant difference on the ozone depletion impact category as the additional launches required to deliver lunar-based infrastructure for META-LUNA balanced out the launches required for META-PRIME. Therefore,ozone depletion is an even more critical impact category to address in future design sessions. As 99.99% of the ozone depletion impact comes from launch, this may mean looking into the feasibility of alternative launcher options.

[0132] However, the drop in environmental impact is mainly due to the fact that manufacturing begins to take place away from Earth. As space LCA currently only considers ecospheric impacts, this lends weight to the argument that perhaps new metrics for measuring the environmental effects of in-space operations should be developed. Regardless, as a result, it was found that the carbon footprint of the META-LUNA concept could drop to as low as 5.13 gCO2e / kWh for the system boundary outlined in Section 3.3.

[0133] 4.2 Meta Platforms for Space Circular Economy

[0134] To date, three platforms of the SPS Architecture have been introduced. Figure 7 is a schematic diagram showing the domains of operations of the three platforms and how they work together, described further below. META-PRIME is developing SPS to deliver power to Earth where the SPS is deployed from Earth to LEO and transported to GEO for self-assembly, METAALCHEMIST is an in-orbit manufacturing and recycling facility with autonomous in-orbit servicing robots to reuse and repurpose materials space debris and deal with logistics, assembly and disassembly of end-of-life components and decommissioning of SPS, and lastly, META-LUNA which is a Self-Replicating Modular lunar factory for manufacturing and recycling of SPS, a transportation network, and autonomous robotics autonomous robotics for logistics and construction of SPS. Each platform operates independently to facilitate a range of useful applications in space. Whereas by combining the platforms we propose the creation of a space circular economy to build, recycle and continually replenish Solar Power Satellites to provide an inexhaustive source of clean energy on Earth and in Space.

[0135] 5. SUMMARY

[0136] By moving manufacturing of Solar Power Satellites to space, the environmental impact of developing SPS to deliver power to the Earth is reduced.

[0137] The META-LUNA concept aims to create a system capable of autonomously producing SPS and its own components, to expand capacity over time, and sustain itself using lunar resources. It features a Self-Replicating lunar factory for manufacturing and recycling of SPS, Transportation Network and autonomous robotics for logistics, maintenance and construction of SPS. Initially, materials from the Earth are transported to the Moon to set up the initial components of the lunar factory. The lunar factory is envisioned to grow overtime using the materials from the Moon and recycling space debris, space systems at the end of life in space such as SPS, satellites and lunar infrastructure.

[0138] By leveraging the Moon's abundant materials, the factory can operate sustainably and with reducing reliance on Earth-based supply chains. By utilizing local lunar resources for SPS production, recycling materials, and minimizing waste, we can create a closed-loop system in space that mirrors sustainable practices on Earth. This is a critical step towards developing afuture sustainable space economy, where space exploration and industrialization become self- reliant, reducing the need to constantly transport supplies from Earth.

[0139] Finally, META-LUNA is a crucial stepping stone to unlocking the broader resources of the solar system, and serves as a launchpad for future exploration and mining of asteroids, moons, and other planetary bodies, opening up vast opportunities for resource extraction and use in space. This will support the long-term growth of human presence in space, ultimately enabling humanity to migrate to space and become a multi-planetary species.

[0140] Referring again to Figure 7, illustrated therein is a schematic diagram of the SPS Architecture Concept of Operations 700 (herein system (700), according to one embodiment.

[0141] System 700 exists in the area of space between the Earth 702 and the orbit of the Moon 704. There are three orbits for components of system 700: low Earth orbit (LEO) 706, geosynchronous orbit (GEO) 708, and lunar orbit 710.

[0142] The three systems of system 700 are META-PRIME 720, META-LUNA 730, and METAALCHEMIST 740, which as described above represent: i) META-PRIME is a system for delivering power to Earth from SPS, ii) META-ALCHEMIST is a system for an in-orbit manufacturing and recycling facility with autonomous in-orbit servicing robots to reuse and repurpose materials space debris and deal with logistics, assembly and disassembly of end-of-life components and decommissioning of SPS, and iii) META-LUNA is a modular lunar factory for manufacturing and recycling SPS, including a transportation network, and autonomous robotics autonomous robotics for logistics and construction of said SPS. Together the three systems or platforms represent a circular economy in space for providing a renewable source of clean energy for Earth and space.

[0143] META-PRIME 720 includes SPS 722 which may include sandwich SPS with solar cells facing either the Sun or reflectors which can reflect solar radiation, and microwave elements facing Earth to send microwave energy to Earth. The SPS 722 are in GEO 708.

[0144] The SPS 722 may be mostly manufactured on Earth and sent into LEO and then to GEO for assembly, or the SPS 722 may be manufactured in space at the lunar factory 732 by METALUNA 730. The lunar factory 732 is on the moon 704.

[0145] META-PRIME 720 also includes SPS 724 which may have the same configuration as SPS 722 but which send microwave energy to the Moon and to META-LUNA 730. The SPS 724 are in lunar orbit 710.

[0146] The lunar factory 732 manufactures SPS and sends them through a transportation network 734 to be used in META-PRIME 720 or both Earth and the Moon. The transportation network exists in both GEO 708 and lunar orbit 710.

[0147] The transportation network 734 also receives space components 736 from GEO 708, e.g., end-of-life SPS, free flyer components, space debris, etc., and sends said space components to the lunar factory 734 to be processed and used for various purposes, including manufacturing more SPS 722 / 724.

[0148] META-ALCHEMIST 740 is a system for in-orbit manufacturing and recycling, which can serve as a factory as well as a fuel station. In Figure 7, a space station 742 (in GEO 708) and other free-flyers may visit META-ALCHEMIST components for refueling. In the manufacturing capacity, META-ALCHEMIST 740 may receive SPS components from the transportation network 734 to assemble fully operational SPS at zero gravity. META-ALCHEMIST 740 may also receive and decommission space components, such as SPS, at end-of-life.

[0149] META-ALCHEMIST 740 is focused on the production of more valuable materials from simple sources, generally utilizing non-organic chemistry. Given the lack of oxygen in space, there is a particular alchemy that can result in production of materials and products in-orbit, which is much better suited to the environment.

[0150] Reusable lunar landers 750 on the Moon may be used by all systems as they can provide propellant manufactured or stored on the Moon to be transported to propellant depots 760 in GEO 708 and lunar orbit 710. The reusable lunar landers 750 may also be used by METALUNA 730 to move materials and SPS components around on the Moon.

[0151] Figure 8 shows the circularity and recyclability provided by META-PRIME 820, METALUNA 830, and META-ALCHEMIST 840 within system 800. These three meta-platforms work together as the basis of the circular space economy. META-PRIME 820 components can be recycled by META-ALCHEMIST 840, and the recycled materials can be used to build METALUNA 830 and / or components manufactured at META-LUNA 830. Products from META-LUNA can be used to build or replenish META-PRIME 820 components.

[0152] One way to improve commercial viability of SBSP is to design solar power satellites (SPS) for ongoing replacement, recycling, and reuse at end-of-life. Several materials used in the construction of SPS can be useful in other technology. If fewer materials were launched into space from Earth, the cost of space-based construction to decrease. Reused material from SPS could be used to support a circular space economy including in-orbit manufacturing and refurbishment. Reused material can also support a cis-lunar economy by enabling lunar infrastructure development and could be expanded further to Mars. In addition to financial incentives, there are political incentives that may encourage the recyclability and sustainability of SPS structures. Meta-Alchemist provides a framework to enable recycling and reusing materials in space to help quantify and optimize the manufacturing, assembly, and disassembly of the SPS. This system establishes a sustainable facility in Earth's orbit to recycle and repurpose various cycles, including spacecraft components, satellites, and other space debris features a modular service station in- orbit where the recycling / manufacturing happens and free flyer service modules that can collect material and repair / disassemble / assemble spacecraft. To deal with current satellites that have reached end-of-life, the alloys and metals from satellites to be recycled in orbit and transformed into other products could be used. Materials will be processed in-orbit and recycled into new products, for example new satellites and / or satellite components for repair and maintenance purposes. By recycling old satellites and spent rocket boosters for additive manufacturing,construction, energy, and fuel, we can remove objects in space that can contribute to future space debris, remove the need to bring the old satellites back to Earth leading to pollution in the upper atmosphere, and create new supply chains to support the space activities. The recyclability of these systems will ensure that old satellites will be useful upon end of life as a feedstock for critical space infrastructure development prioritizes the reuse, repair, refurbishment, and recycling of materials to extend their lifecycle, is particularly crucial in the space industry to address the growing issue of space debris and contribute to sustainable space exploration. Satellite bodies are primarily made of aluminum >90%, a metal fuel in thermite reactions. The aluminum is in an alloy form that may include Cu, Mg, Zn, Mn, Si, Fe, Cr, Ti, and Zr. When processed into fine powders this material can act as a power for metal additive manufacturing (powder bed fusion) or as a reacting particle in chemical reactions (with metal oxide or lunar regolith). Additionally, these materials can be combined with regolith from the Moon as an oxidizer to create other products to also support the cislunar economy. The flexible architecture enables multiple service stations to be deployed to augment the capabilities of the overall system, for instance, a service station at GEO graveyard to service the earth and another station placed in cislunar which can also service the Moon.

[0153] Meta-Alchemist promotes resource efficiency, waste reduction, closed-loop systems, extended product lifecycles, innovation, collaboration, economic opportunities, and environmental responsibility in the context of space exploration and utilization. The integrated approach can contribute significantly to sustainable space practices and the responsible management of space resources. By reclaiming and repurposing materials from space debris instead of relying solely on new resources from Earth. This aligns with the Circular Economy's goal of optimizing resource use. Additionally, space debris, including defunct satellites and spent rocket stages, contributes to the growing amount of waste in Earth's orbit. The recycling station actively works towards minimizing space debris by recycling and reusing these components, adhering to waste reduction principles.

[0154] Meta-Alchemist aims to create closed-loop systems in space, where materials are continuously recycled and reused, that minimize the extraction of new resources and reduce waste by keeping materials in circulation. Through the recycling and repurposing of cycles, the project contributes to extending the lifecycle of space materials, focusing on prolonging the usability of products and components, and transforming them into useful products to support the circular economy in space. The space station for in-orbit refurbishment, manufacturing, and recycling involves the deployment of a modular and autonomous orbital service station equipped with specialized modules for different purposes comprising flight segment, manufacturing, manufacturing, recycling, and propellant depots. The flight segment module includes: a processing center (robotic arms with advanced sensor packages for repair / disassemble / assemble), power systems (solar panels and power storage system (solar array drive, batteries and power distribution system), a thermal control system, a propulsionsystem (pressurized propellant tanks (includes valves, piping, regulators, and transducers) and an integrated reaction control thruster, sensors (infrared earth sensor, inertial momentum unit, analog sun sensor, and lidars, cameras), telemetry, tracking and communication (phased array transceivers (Ku-Band and S-Band), Ku-Band beacon transmitter, and S-band transponder, and onboard computer driven by artificial intelligence for precise satellite command and control. A refurbishment module includes robotics arms and swappable end-effectors with tools for repairing or replacing faulty components and diagnostic equipment to assess satellite health using computer vision and artificial intelligence. A manufacturing module integrates 3D printing technology using induction-based technologies and assembly arms for on-orbit manufacturing and satellite construction. A recycle module includes cutting processes (lasers are utilized to efficiently and safely dissemble satellite components). Calibration and alignment of the laser system are crucial, ensuring precise targeting of laser beams on specific components based on the satellite's material composition. Algorithms for optimal cutting sequences and real-time monitoring of the laser cutting process maximizes efficiency while minimizing the release of debris. To meet the appropriate ranges of required power levels to match material compositions, the laser system is outfitted with optics. In other implementations, cutting processes may employ masers or other electromagnetic radiation sources. The system includes mechanisms for debris containment & thermal management, with cooling systems in place to address heat generated during laser cutting. Quality control and inspection steps, supported by sensors and cameras, verify the integrity of salvaged materials. The laser-cut satellite components are then directed to shredding processing sections within the recycling module using robotic arms). The shredding process includes a series of crushing gears for large and fine shredding of materials, slicing blades for cutting, and containment systems for the disassembly of defunct satellites, aimed at reducing space debris and recovering valuable materials. An electrostatic particle separator may be used wherein once materials have been shredded into the desirable particle sizes, metallic and non-metallic particles are separated using electric field forces. Magnetic separation may be employed using electromagnets, or magnetic and non-magnetic particles). Ball millers may be used wherein magnetic particles are directed into a ball mill, which is wrapped with induction coils connected to power circuitry and a cooling system for precise temperature control, usable materials are melted, and ball milled into micropowder. Materials may be stored in storage tanks wherein processed materials are directed into materials storage sections to support new applications. Additive manufacturing may be employed wherein micropowder can be processed into additive manufacturing feedstock. Fuel production may be performed wherein micropowder can be mixed with metal oxides, with metal oxides brought from Earth and / or secured from supply chains from the Moon, Mars, and / or asteroids.

[0155] Propellant depots collect, refine, store, and dispense propellants produced from recycled space debris and locally-sourced materials. The propellant depots act as a logistics hub for spacecraft and free-flying servicers, extending mission lifetimes, enabling orbital maneuvering,and supporting assembly and exploration missions by providing on-demand fuel and propulsive modules manufactured on site. Feedstock comes from two primary sources: (1) recovered objects and fragments collected by servicers and capture vehicles and (2) in-situ resource extraction from nearby space resources (Moon, Mars, and asteroids). The depot’s primary purpose is to receive, store, manage, and dispense refined materials while maintaining seamless connections with a network of free-flying servicers, tugs, and manufacturing vehicles operating in its orbital vicinity. Integrated into the station’s modular architecture, the depot links directly to neighboring modules dedicated to materials processing, manufacturing, and robotic operations. The depots serve as the interface layer between on-orbit production systems and mobile spacecraft, bridging the flow of physical resources throughout the ecosystem. Docking ports and standardized utility corridors connect the depot to other station modules, while external nodes and refueling arms enable multiple simultaneous docking operations with free-flyers. The depot’s primary function is to store refined propellant products and raw material stocks recovered from debris or resourcemining missions. Internally, the depots house segregated storage tanks for cryogenic and storable propellants, pressurized containment units for gaseous feedstocks, and dry cargo bays for solid materials awaiting reprocessing. Advanced thermal control systems maintain stable temperatures for cryogenic fluids, while intelligent pressure management and automated valve networks regulate transfer operations. A digital inventory management system continuously tracks mass balance, purity, and flow rates of all materials in real time, coordinating with both station control and approaching vehicles. The system also maintains a closed-loop supply chain, returning unused materials or by-products back to relevant processing modules for refinement or reuse. Externally, the depots feature multiple standardized docking and refueling interfaces compatible with a wide range of visiting spacecraft including satellite servicers, tankers, debris collectors, and cargo drones. Robotic booms equipped with universal fluid couplers, electrical interfaces, and data links facilitate propellant transfer, component delivery, or material exchange. The depots act as the central logistics hub for all free-flying activity in the station’s vicinity, assigning approach trajectories, handling authentication, and orchestrating rendezvous sequences through a secure autonomy coordination network. In practice, this allows servicers to offload collected debris feedstock, take on refined propellants, or receive modular resource canisters for delivery to other clients or orbital platforms. The propellant depots may be integrated into the space station and or may be an independent system.

[0156] Free flyer service modules are built around a rigid central structure that houses its avionics, propulsion, power, and robotic systems. The structure and a thermal subsystem provides a stable, insulated platform with modular attachment points for tools and spare components. A propulsion system includes both high-thrust engines for orbit transfers and fine-control micro-thrusters for precise rendezvous and proximity operations. Guidance, navigation, and control (GNC) rely on star trackers, inertial sensors, cameras, and LIDAR to enable autonomous approach, docking, and manipulation. Power is supplied throughdeployable solar arrays and high-density batteries, managed by a power distribution unit that delivers regulated energy to all subsystems and tools. A robotic manipulation system includes any one or more dexterous multi-jointed arms equipped with interchangeable end-effectors — ranging from grappling mechanisms to specialized tools for refueling, cutting, fastening, and inspection. A docking and capture subsystem allows the servicer to securely attach to client satellites using standardized grapple fixtures or capture rings. The servicer’s computing and autonomy stack combines radiation-tolerant flight computers with advanced onboard processing to perform perception, motion planning, and fault detection, enabling both supervised and fully autonomous operations. Communications systems support high-bandwidth links to Earth or relay satellites for command, telemetry, and data transmission. A suite of sensors and inspection instruments — including high-resolution cameras, thermal imagers, LIDAR, and borescopes — allows detailed visual and structural assessments of client spacecraft. Finally, payload and storage modules provide internal or external bays for carrying spare parts, modular tools, and replacement subsystems.The servicer is capable of delivering, installing, or replacing a wide range of satellite subsystems and payload components. These include avionics modules such as flight computers and control electronics, communications packages like transponders and high-gain antennas, and power system elements such as battery packs, solar array segments, and power distribution units. The servicer can also service attitude and orbit control hardware, including reaction wheels, star trackers, magnetorquers, and inertial measurement units. For propulsion-related support, the servicer can refuel client spacecraft by transferring stored propellants through standardized quick-connect interfaces or replace small propulsion modules such as thruster pods or pressure regulators. The servicer can install or repair thermal control components, including heaters, radiator panels, and multilayer insulation patches. The system can also handle payload and structural upgrades, delivering or swapping scientific instruments, camera units, or lightweight structural members such as booms and brackets. In addition, the servicer can perform software updates or reflash on-orbit computers, deploy deorbit or debris mitigation kits, and install modular add-ons to extend satellite functionality or mission life.

[0157] Referring to Figure 9, illustrated therein is a flowchart showing an example workflow of a META-LUNA system according to the embodiment in FIG. 3.

[0158] At 902, input materials are received by a lunar factory on the Moon. The input materials may be any materials within space that can be used to manufacture or assemble new space components. The input materials may include lunar regolith, other lunar infrastructure, end-of-life space systems including SPS, space debris, and other space resources. Ancillary services of the META-LUNA system may perform extraction of the input materials, such as extracting lunar regolith from the lunar surface.

[0159] At 904, the input materials are preprocessed. This may include sorting the input materials by type, size, density, composition. The sorting systems may be automated Al-drivensensor based systems. The preprocessing may also include crushing or grinding of materials as necessary. Preprocessing would be performed by a preprocessing module which may include submodules. The submodules may include magnetic separators, electrostatic separators, filters, dewatering systems, drying systems, etc.

[0160] At 906, 908, 910, and 912, the preprocessed materials are sent to downstream modules of the lunar factory.

[0161] At 906, a material processing module processes the preprocessed material to generate processed materials. Material processing may include in-situ resources processing methodologies such as: carbo-thermal methods, molten-regolith electrolysis, FFC Cambridge method, vapor phase pyrolysis, solar smelting, and / or water electrolysis to create high-purity metals, ceramics, oxygen, ceramic, glass, semiconductors, polymers, and / or alloys for manufacturing components and / or for maintaining and replicating the lunar factory.

[0162] At 908, a recycling module recycles the preprocessed material to generate recycled materials. The recycling module processes and repurposes waste materials, defective parts, and space systems components at the end-of-life. The primary function of the recycling module is to ensure a closed-loop system that minimizes waste and maximizes resource efficiency, which is essential for sustained operations in the resource-scarce environment of the Moon.

[0163] At 910, an additive manufacturing module performs additive manufacturing with the preprocessed material to generate additively manufactured components. 3D Printing technologies can be used for on-demand manufacturing of robotic systems, satellite components, factory parts and tools could be derived directly from metal powders extracted from lunar soil, or metals created via processing of input materials.

[0164] At 912, preprocessed materials are stored in a storage module, as stored materials / components.

[0165] Also, within 906-912 any of the outputs following the actions of the modules on the preprocessed materials, i.e., the processed materials, the recycled materials, the additively manufactured components, and the stored materials / components may be used as in put to the other modules.

[0166] That is, the material processing module may receive and process recycled materials, additively manufacture components, and stored materials / components.

[0167] The recycling module may receive and recycle processed materials, additively manufactured components, and stored materials / components.

[0168] The additive manufacturing module may receive and perform additive manufacturing with processed materials, recycled materials, and stored materials / components.

[0169] The storage module may receive and store processed materials, recycled materials, and additively manufactured components. At 914, the outputs of 906-912 may be autonomously assembled to integrate parts and components manufactured at 906-912 into fully operational components of SPS, for example reflectors, solar cells, and microwave elements, ready for usein space. An autonomous assembly module includes robotic arms, sensors, and Al systems to correctly and efficiently assemble the SPS components.

[0170] At 916, SPS components or fully formed SPS are transported to lunar orbit and if necessary to Earth orbit. SPS components may be transported to a second in-orbit assembly system to be fully assembled. Transportation occurs in a transportation network including reusable lunar landers and space tugs which can also perform return trips to bring input materials to the lunar factory.

[0171] At 918, SPS are assembled from sub-components at the in-orbit assembly system. The sub-components may be delivered to the in-orbit assembly system by the transportation network. Assembly in-orbit at zero gravity may be desired over assembly with gravity.

[0172] At 920, the final output of the META-LUNA system is a fully assembled SPS. However, the system may output other components, for example, new space system and components for non-SPS purposes, propellant, metals and alloys, and water.

[0173] At any step, autonomous robots may aid in the manufacturing of SPS. For example, autonomous robots may transport materials between mining sites, processing plants, and launching pads. Autonomous robots may perform tasks such as welding, cutting, and electrical system integration. Autonomous robots may be capable of real-time maintenance and repair of other lunar factory components.

[0174] In some implementations, the factory of employs a suite of Al systems that enable full autonomy, adaptability, and optimization across its operations. Perception and Sensing Al systems interpret data from visual, multispectral, and geophysical sensors to identify mineralrich regolith deposits, monitor process integrity, and ensure safe navigation of autonomous rovers and manipulators. Planning and Scheduling Al coordinates mining, processing, and manufacturing activities, dynamically adjusting to changes in resource availability, system health, and production demands to maintain continuous operation. Process Optimization Al manages refining, electrolysis, and additive manufacturing parameters in real time, learning from performance data to maximize output efficiency and energy utilization. Robotic Control and Manipulation Al governs autonomous assembly units and precision handling systems, enabling the construction, repair, and replication of factory components, habitats, and orbital payloads. Predictive Maintenance Al continuously monitors mechanical, thermal, and electrical systems, using anomaly detection and failure prediction models to preempt breakdowns and extend hardware lifespan. Cognitive Design Al supports generative engineering of space systems and infrastructure, producing optimized component geometries and material compositions based on mission profiles and available in-situ materials. Swarm Coordination Al enables distributed operation among multiple robotic units and sub-factories, ensuring synchronized workflows and efficient resource allocation. Finally, Ethical and Governance Al ensures adherence to mission safety protocols, environmental stewardship principles, and long-term lunar sustainabilityobjectives, providing oversight for autonomous decision-making and system-level replication controls.

[0175] In another implementation, the self-replicating factory is an autonomous, modular manufacturing system designed to operate in space, on the lunar surface, on the Martian surface, on asteroids or in other extraterrestrial environments. The factory is capable of extracting, refining, manufacturing, assembling, and recycling materials using in-situ resources or imported feedstocks to produce space systems, infrastructure, and additional factory modules for selfreplication. The factory is composed of six primary subsystems: pre-processing, material processing, recycling, additive manufacturing, storage, and autonomous assembly. Together, these subsystems form a closed-loop Mine-to-Waste Processing Chain that transforms raw materials into finished products while minimizing waste and maximizing resource reuse. The preprocessing module performs surveying, acquisition, and initial preparation of source materials. On the lunar surface or asteroid environments, this includes mining and regolith beneficiation through particle classification, magnetic and electrostatic separation, and volatile control. In orbital operation, the same subsystem interfaces with captured asteroidal material or recycled debris, using robotic manipulators and mechanical grinders to prepare feedstock for processing. The material processing module converts raw feedstock into usable elemental and compound products. Processes include molten regolith or molten oxide electrolysis for oxygen and metal extraction, vapor-phase refining for volatile recovery, and electrolytic or catalytic reactors for producing hydrogen, oxygen, and hydrocarbon propellants. This module also performs alloying, purification, and compositional control to create standardized metallic, ceramic, and composite materials. The recycling module reprocesses decommissioned systems, damaged components, and manufacturing waste. Automated dismantling and re-melting operations reclaim metals and composites, while gaseous and liquid by-products are filtered and reintroduced into the production cycle. Inert or unusable waste is vitrified or compacted into radiation shielding, construction blocks, or reaction mass for propulsion, ensuring a near-zero-waste operation. The additive manufacturing module fabricates precision components and structures using refined feedstocks. Techniques include directed energy deposition, microwave sintering, selective laser sintering, fused filament fabrication, and regolith or debris-based 3D printing. Outputs range from truss structures, panels, and radiators to tanks, valves, and phased array substrates. Generative design algorithms within this module optimize part geometry for strength, efficiency, and material utilization. The storage module provides environmental and thermal regulation for intermediate and final products, including cryogenic propellants, refined metals, water, and modular components. Al-controlled inventory systems coordinate with the manufacturing and assembly cycles to balance production demand, resource flow, and self-replication schedules. The autonomous assembly module uses robotic manipulators, mobile constructors, and swarm robotics to assemble completed systems and deploy them for operational use. Depending on configuration, the factory can produce and assemble outputs such as solar power satellites,propulsion stages, structural modules, radiation shielding elements, and other space system components. This same assembly framework enables the factory to fabricate and integrate new factory modules, allowing for scalable self-replication and distributed network growth. Al systems govern the entire Mine-to-Waste Processing Chain. Perception Al monitors material inputs and environmental conditions; Planning and Optimization Al manages production flow, energy allocation, and maintenance; Robotic Control Al supervises construction and handling tasks; and Generative Design Al evolves new designs adapted to locally available materials and mission requirements. The factory converts natural and artificial space materials into functional systems, infrastructure, and replicated production capacity. The resulting capability establishes a foundation for autonomous industrial growth in orbit, on the Moon, and throughout the solar system.

[0176] The factory enables the creation of entirely new classes of technologies specifically optimized for the space environment, rather than adaptations of terrestrial designs that must be over-engineered to survive launch and transport through Earth’s atmosphere. Leveraging, locally sourced materials and autonomous manufacturing, the factory can design, fabricate, and assemble systems that take full advantage of the unique conditions of space such as microgravity, vacuum, and abundant solar energy.

[0177] While the above description provides examples of one or more apparatus, methods, or systems, it will be appreciated that other apparatuses, methods, or systems may be within the scope of the claims as interpreted by one of skill in the art.

Claims

Claims:1 . A factory system for manufacturing and recycling space systems in space, comprising: a factory including: a preprocessing module configured to receive input materials, classify the input materials, and sort the input materials by classification; a storage module configured to receive preprocessed input materials from the preprocessing module; a material processing module configured to receive preprocessed input materials from the preprocessing module and the storage module to undergo a transformation into a processed material to be used as part of a space system; wherein the storage module is further configured to receive processed material from the material processing module; and an autonomous assembly module configured to receive processed material from at least one of the material processing module and the storage module and to assembly at least one of a space system and components of a space system.

2. The system of claim 1 wherein the factory is on the Moon.

3. The system of claim 1 wherein the space system is a solar power satellite (SPS).

4. The system of claim 1 wherein the space system is the factory and the autonomous assembly module assembles components for the factory.

5. The system of claim 1 wherein the input materials include at least one of: lunar regolith, lunar infrastructure, end-of-life solar power satellites, end-of-life space system components, space debris, and space resources.

6. The system of claim 1 wherein the preprocessing module includes systems to cut, crush and / or grind input materials into particles and / or powders.

7. The system of claim 1 , wherein the preprocessing module include at least one submodule from at least one of: magnetics separators, electrostatic separators, and filters.

8. The system of claim 1 wherein the material processing module performs at least one of: carbo-thermal methods, molten-regolith electrolysis, FFC Cambridge method, vapor phase pyrolysis, solar smelting, and water electrolysis.

9. The system of claim 1 wherein the material processing module generates at least one of: high-purity metals, oxides, oxygen, ceramic, glass, semiconductors, polymers, and alloys.

10. The system of claim 1 wherein the autonomous assembly module include robotic systems.

11. The system of claim 1 wherein the autonomous assembly module perform automated quality control and testing.

12. The system of claim 1 wherein the autonomous assembly module uses artificial intelligence (Al) system and sensors to control and monitor the assembly of space systems and components.

13. The system of claim 1 further comprising a recycling module configured to receive end-of- life input materials and to process the end-of-life input materials to base components to be used in a new space system.

14. The system of claim 13 wherein the material processing module receives base components from the recycling module.

15. The system of claim 1 further comprising an additive manufacturing module configured to receive preprocessed materials from the preprocessing module and to create components from the preprocessing materials by additive manufacturing.

16. The system of claim 15 wherein the materials for additive manufacturing include at least one of a metal including silicon, aluminum, iron, calcium, magnesium and titanium, and a metal oxide including SO2, AI2SO2, TiO2, MgO, CaO, FeO, Na2O, K2O, P2O2, Cr2O3, MnO.

17. The system of claim 1 further comprising a transportation network which transports space systems and space system components from the factory into orbit and from orbit to the factory.

18. The system of claim 17 wherein the transportation network includes lunar landers to transport materials on the Moon.

19. The system of claim 18 wherein the transportation network includes space tugs configured to carry materials, space debris, recyclable materials, and customer payloads to the moon.

20. The system of claim 19 further comprising propellant depots in-orbit.

21. The system of claim 17 further comprising an in-orbit assembly system to receive space components and to assembly space systems from the space components.

22. The system of claim 1 further comprising autonomous robots for transportation of materials between modules and launching pads.

23. The system of claim 1 further comprising autonomous robots configured to perform tasks including welding, cutting, and electrical integration.

24. The system of claim 1 further comprising a plurality of ancillary services systems including at least one of power systems for providing power to the factory, resource extraction systems for extracting resources, command and control systems for controlling the factory, maintenance systems for monitoring and maintaining the factory, and a digital twin system located on Earth which provides a digital record of the factory for monitoring the factory in near real-time.

25. The system of claim 24 wherein the digital twin system enables simulation of a virtual environment for testing operational processes of the factory system.

26. The system of claim 1 wherein the factory replicates new environmentally adaptive systems configured to learn from operation data to improve efficiency, yield, and energy utilization in material processing, additive manufacturing, and assembly operation over time.

27. The system of claim 26, wherein the factory includes an Al-driven control system configured to utilize reinforcement learning to optimize task scheduling, resource allocation, and replication sequences based on feedback from prior production cycles.

28. The factory of claim 27, wherein the Al-driven control system updates process parameters, such as temperature, feed rate, or additive manufacturing scan patterns, based on realtime monitoring and historical performance data.

29. The factory of claim 27, wherein the Al-driven control system employs predictive modeling to anticipate maintenance needs, material shortages, or process failures and adjusts operations proactively.

30. The factory of claim 27, wherein learning is applied to the design of new components, structures, or factory modules, enabling the system to generate improved geometries, material combinations, or assembly methods for future production.

31. The factory of claim 27, wherein multiple self-replicating factories share learned operational data in a federated learning framework to collectively improve efficiency, replication fidelity, and output quality.

32. The factory of claim 27, wherein the Al-driven system continuously adapts the Mine-to- Waste processing chain, including recycling strategies and material routing, to optimize yield and minimize waste based on prior processing outcomes.

33. The factory of claim 27, wherein learning algorithms evaluate environmental conditions, such as solar flux, radiation, or microgravity effects, and modify operational strategies to maintain consistent performance and system integrity.

34. The system of claim 15, wherein the additive manufacturing module is adapted to fabricate radiation shielding elements comprising sintered regolith blocks.

35. The system of claim 1 , further comprising a robotic assembly module configured to assemble fabricated structural parts into modular lunar infrastructure selected from the group consisting of landing pads, roads, habitat foundations, and mass driver components.

36. The system of claim 1 , further comprising a factory control module configured to implement a replication orchestration routine that dynamically allocates factory output between production of externally deliverable space systems and production of components for self-replication according to an energy-based priority metric.

37. The system of claim 1 , further comprising a powdered metal production module configured to atomize refined melts into metal powder having a controlled particle size distribution suitable for additive manufacturing.

38. A method for producing space system components in space, the method comprising: producing products such as metals, metal oxides, oxides, composites, and alloys, recovered from space resources; using additive manufacturing to produce structural members and modular component frames from the recovered products; integrating printed structural members with electronics and fluidic subsystems in a robotic assembly to form replaceable spacecraft components; and performing non-destructive evaluation and functional testing of the formed replaceable spacecraft components prior to storage or transfer.

39. The method of claim 38, wherein producing products comprises extracting metals and volatiles from regolith, asteroid material, or recycled spacecraft components.

40. The method of claim 38, wherein additive manufacturing includes at least one of the following: microwave sintering, selective laser sintering, directed energy deposition, or binder-assisted printing.

41. The method of claim 38, further comprising sintering printed components using thermal, microwave, or solar-concentrated energy to increase density and mechanical strength.

42. The method of claim 38, wherein robotic assembly employs swarm coordination, Al-driven manipulators, and vision-based alignment for component integration.

43. The method of claim 38, further comprising monitoring all production and assembly steps with Al-based process optimization and predictive maintenance systems.

44. The method in claim 38, wherein the products include is at least one of the following: solar power satellites, space architecture, propulsion stages, structural trusses, radiation shielding elements, space infrastructure on the moon,45. The method of claim 38, further comprising storing the tested spacecraft components in thermally regulated, vacuum-compatible containers for later deployment.

46. The method of claim 38, wherein the method is performed by a self-replicating factory capable of producing additional factory modules autonomously using recovered space resources.

47. The method of claim 38, further comprising continuously learning from production and testing data to adapt fabrication parameters and improve yield, quality, and energy efficiency.

48. The system of claim 1 wherein the factory is on Earth’s orbit.

49. The system of claim 1 wherein the factory is on Moon’s orbit.

50. The system of claim 1 wherein the factory is in a Cis-Lunar orbit.

Images