E-beam PVD Metallic Shell for Inflatable Space Structures
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Solution Overview
Problem
Current methods for manufacturing large structures in space require numerous small modular parts due to weight constraints, limiting the size of structures and increasing manufacturing and shipping costs.
Innovation Solution
A kit comprising an inflatable bladder, a structural liner, and e-beam physical vapor deposition systems is used to form a metallic structural shell on the structural liner, allowing for the creation of larger structures in space with reduced weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If numerous small modular parts are used to manufacture large structures in space, then weight constraints are satisfied for launch, but the size of manufacturable structures is limited and manufacturing/shipping costs increase
Solution Approach 1:
The structural liner is deployed and positioned in advance within the inflatable bladder before the metallic shell is formed. This preliminary deployment allows the liner to be ready as a substrate for subsequent material deposition, enabling the construction of large structures without requiring complex pre-assembly of multiple modular parts in space
Solution Approach 2:
The patent replaces mechanical assembly of numerous modular parts with a material deposition process. Instead of manually or robotically assembling many small components in space, the metallic shell is formed by depositing material onto the deployed structural liner, significantly reducing the complexity of in-space manufacturing operations
2Ease of manufacture
If numerous small modular parts are assembled in space, then weight constraints are met, but manufacturing and shipping costs increase
Solution Approach 1:
The structure is segmented into two main components: the structural liner and the metallic shell. The liner is launched in a compact deployed state and then expanded in space, while the metallic shell is formed in situ through material deposition. This segmentation allows the majority of the structure to be manufactured in space rather than launched fully assembled, reducing launch weight and manufacturing costs
Solution Approach 2:
The patent changes the physical state and location of material deposition. Material is deposited in the vacuum of space directly onto the deployed structural liner, forming the metallic shell. This parameter change from Earth-based manufacturing to in-space deposition eliminates the need for expensive launch of pre-manufactured components and reduces overall manufacturing costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the manufacture of larger space habitats with reduced weight and cost, providing a structurally durable and safer structure with a rigid interior surface suitable for integration with other systems.
Implementation Method 1
one or more e-beam physical vapor deposition systems configured to form a metallic structural shell on the structural liner
Implementation Method 2
e-beam physical vapor deposition systems configured to form a metallic structural shell
Data Source
AI summary
A kit for manufacturing a structure in space is provided. In one aspect, the kit includes an inflatable bladder having an internal wall configured to define an internal space of the structure when the bladder is inflated. The kit also includes a structural liner coupled to the internal wall of the inflatable bladder. The kit also includes one or more e-beam physical vapor deposition systems configured to be positioned within the internal space of the structure when the bladder is inflated. The one or more e-beam physical vapor deposition systems configured to form a metallic structural shell on the structural liner.