While the last human moon landing occurred in December 1972 with Apollo 17, advanced manufacturing technologies will be crucial for future crewed missions to Mars, especially as NASA continues to advance robotic missions.

This research also supports in-situ resource utilization on the Moon, enabling construction and repair using locally sourced materials like regolith.

Researchers from Ohio State University have tested a robotic laser welding machine during parabolic flights to simulate microgravity, assessing its effectiveness with materials like aluminum, titanium, and stainless steel, which are commonly used in spacecraft.

In-space manufacturing is poised to revolutionize space exploration by enabling repairs and construction of spacecraft in orbit, which could significantly reduce the need for transporting parts from Earth and lower overall mission costs.

The high costs of space travel have historically limited human exploration since the Apollo program, making innovative solutions like in-space manufacturing essential for feasible future missions.

NASA is focusing on in-space manufacturing technologies, such as welding and additive manufacturing, to create large habitats in low Earth orbit and to repair and repurpose existing space infrastructure.

This project addresses three primary challenges: the impact of low temperatures on the weldability of aluminum alloys, the alteration of keyhole geometry during welding in vacuum conditions, and the effects of microgravity on gas escape from molten metal, which can lead to defects.

Data collected from these tests includes critical factors such as temperature and heat transfer in a vacuum, the characteristics of the molten area during welding, and the mechanical properties of the finished welds under space-like conditions.

To enhance the reliability of their findings, the team employs multi-scale multi-physics models combined with machine learning to develop a real-time digital twin platform for evaluating welding processes in space.

The ultimate goal of this research is to minimize trial-and-error in welding, improve the quality of one-shot welds, and reduce both costs and time associated with space missions.

Overall, in-space manufacturing and assembly are critical components of NASA's exploration missions to both the Moon and Mars, paving the way for sustained human presence beyond Earth.

Despite a negative perception of manufacturing, it plays a vital role in aerospace, particularly in supporting U.S. space flight and future missions to the Moon and beyond.