University of Florida Engineers Innovate Laser Technology for Space Manufacturing

In a groundbreaking initiative that could revolutionize space construction, engineers from the University of Florida (UF) are advancing laser-forming techniques to bend metal sheets into substantial structures in orbit. This project, known as NOM4D (Novel Orbital and Moon Manufacturing, Materials, and Mass-efficient Design), is backed by the Defense Advanced Research Projects Agency (DARPA) and NASA's Marshall Space Flight Center. It aims to enable the manufacturing of large-scale structures like solar arrays and satellite antennas directly in space, thereby bypassing the limitations imposed by rocket size and weight.

The NOM4D project is spearheaded by Dr. Victoria Miller, an associate professor in the Department of Materials Science and Engineering at UF's Herbert Wertheim College of Engineering. "To build big things in space, you must start manufacturing things in space. This is an exciting new frontier," Dr. Miller stated, emphasizing the project’s significance in transforming space infrastructure development.

Currently, UF engineers are working to overcome the challenges of rocket cargo limitations by utilizing laser technology to create precise patterns on metals, allowing them to bend into the desired shapes without physical contact. "With this technology, we can build structures in space far more efficiently than launching them fully assembled from Earth," noted Nathan Fripp, a third-year Ph.D. student involved in the project.

The research, which commenced in 2021, has made notable progress, although further development is required before the technology can be implemented in actual space missions. The research team is conducting controlled tests on materials such as aluminum, ceramics, and stainless steel to understand how different variables affect their behavior during the laser-forming process. The results from these tests will help ensure the structural integrity of the manufactured components.

As part of their collaboration with NASA, UF researchers have access to a thermal vacuum chamber that simulates space-like conditions, significantly aiding in technology readiness assessments. The ability to test laser forming in such an environment is crucial for adapting the manufacturing techniques to the challenges posed by space, including extreme temperatures and microgravity.

The NOM4D project has received a $1.1 million contract from DARPA, and as it approaches its conclusion in June 2026, the UF team remains optimistic about the future of space manufacturing. "Each simulation and laser test brings us closer to a new era of construction not just on Earth, but beyond," said Tianchen Wei, another Ph.D. student working on the project.

This innovative approach to space construction not only enhances the feasibility of long-duration missions but also paves the way for sustainable operations in orbit. As the NOM4D project progresses, it stands to redefine our understanding of manufacturing in space and could lead to significant advancements in satellite technology and future extraterrestrial habitats.