Tubular Truss In Space Manufacturing

Opterus is developing patent pending Tubular Truss Additive Manufacturing (TTAM), an architecture for the in-space manufacturing of large, high-performance space trusses. TTAM solves the challenge of achieving mass efficient large space platforms for space solar power, telescope apertures, and communications and sensing platforms scaling up to a kilometer in size. TTAM is suitable for lunar and Mars surface structures as well. TTAM uses high performance collapsible tubular masts (CTMs) as the feedstock material instead of solid or tape filaments. CTMs are thin shell high strain composite (HSC) tubular struts that flatten and roll stow for extremely compact feedstock packaging. The baseline TTAM fusing method is removable mechanical fasteners, which inherently require very little energy input. A specialized fastener has been designed that is easily installed or removed by the TTAM printhead; allowing easy repurposing and reuse of CTM struts. The fastener also provides a mechanical interface and attachment point for the primary system components: solar panels, utilities, reflector/mirror segments, and tension elements. This paper presents performance estimates and preliminary TTAM printhead designs, and a prototype truss fabricated using the TTAM approach.