This patent introduces an innovative
system for
solar energy-assisted cold spray additive manufacturing,
coating, and repair purposes. The
system is designed for both extraterrestrial and terrestrial applications, leveraging the efficient utilization of the
solar energy and in-situ resources for manufacturing processes. The comprehensive
system integrates multiple technologies, including a cold spraying unit, a
solar energy-based air / gas compressing unit, a unit for
solar light collection, guiding, and amplification, a
solar furnace unit, a
solar cell for electrical energy unit, commercial
powder / local soil collection and sieving unit, robotic units for guiding, communication, materials transport purposes, and a
dry ice and
carbon dioxide gas reservoir with solar energy-based
heating system. The invention is particularly suited for use on Mars, utilizing the
planet's atmospheric
carbon dioxide and
solid carbon dioxide (i.e.,
dry ice, which can be sublimed to gaseous carbon dioxide) to be used as the carrier gas for the spraying process. This approach minimizes the need for transporting materials from the Earth, addressing a significant challenge in
space exploration and
colonization. The system includes solar energy-based scanners to preheat the substrate surfaces and deposited
layers, reducing thermal stresses and enhancing the
interfacial bonding between the deposited
layers and the substrate. This invention offers a sustainable and efficient solution for manufacturing and repairing components and structures in space, supporting the growing interest in extraterrestrial exploration and habitation.