Developing in orbit manufacturing methods for sustainable composites for space applications

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Sustainability is becoming an increasing concern for the space industry as it grows. However, the strict performance requirements of the space application arising from mass and environmental constraints pose a significant challenge. Current spacecraft are made using non-recyclable materials and are either demised or written off at their end-of-life. This solution has been satisfactory for earth-orbiting missions; however, in-situ use/reuse of existing material may become obligatory for long-duration or indefinite missions.This project aims to develop and investigate an in-orbit manufacturing method as a potential alternative to the current paradigm. A successful method could unlock the ability to create large, efficient structures without the penalties associated with the launch and manufacture of virgin material. While the scope of this PhD is primarily focused on space applications, such a method could also have significant implications for the terrestrial sustainability of composites, which are currently widely used in the aerospace and wind energy sectors.The proposed concept combines the WrapToR manufacturing method's structural efficiency with discontinuous fibre composite's recyclability and performance enabled by the HiPerDiF alignment process. To date, no group has demonstrated a system simultaneously capable of comparable structural efficiency and recyclability. To develop this concept, the project aims to tackle the following challenges: 1. Identify and develop a discontinuous fibre thermoplastic composite suitable for space application and manufacturing. 2. Develop a method capable of consolidating aligned HiPerDiF tapes and thermoplastic into a usable filament feedstock. 3. Modify the WrapToR process to be compatible with a thermoplastic input material.