Scientists from The Institute of Materials and Machine Mechanics of the Slovak Academy of Sciences (ÚMMS SAV) are launching a new research project focused on developing robotic stud welding technology in high-vacuum conditions for space applications directly in orbit. The goal is to experimentally verify a solution that could in the future enable autonomous satellite repairs and more efficient removal of space debris from orbit.
Slovak researchers are working on a project called “Robotic Simulator for Experimental Testing of Stud Welding in Vacuum” (ROBSIM – SPACE), focusing on welding in extreme vacuum conditions on various structural materials, including applications through non-conductive layers. The project is supported by nearly €1.5 million from the Program Slovensko.
“The main focus of the project is to create a robotic simulator that allows experimental testing and optimization of stud welding processes on model surfaces of space structures. The researchers aim to develop a scalable vacuum chamber with a larger volume and a robotic arm integrated into the chamber workspace,” said Bednár, adding that the device will be equipped with a unique specialized end effector capable of stable operation in vacuum conditions.
The project builds on existing capacitive stud welding technology — a method that does not require adhesives or screw joints, is energy-efficient, and creates strong bonds in a short time. “This project will advance our previous activities in cooperation with the European Space Agency to a higher level. Our goal is to verify system functionality under laboratory conditions and create a technological foundation for its potential future use in orbital and lunar missions,” explained institute director and project guarantor Naďa Beronská.
According to ÚMMS SAV researcher Marek Gebura, the technology under development could be applied in two key areas of space activity. “The first is active debris removal (ADR), where robotic arms will be able to weld connecting elements onto non-functional satellites, allowing their capture and subsequent removal from orbit. The second is in-space manufacturing and assembly (ISAM), which enables the construction of large structures directly in space or building infrastructure on the lunar surface without direct astronaut assistance,” he said.
A unique feature of the project is the ability to weld through non-conductive layers, such as multi-layer insulation blankets (MLI) or protective coatings used on satellites. These layers have so far represented a significant technological barrier to implementing the technology in on-orbit servicing missions. The project also builds on previous research collaborations with partners including Slovak company Space scAvengers, German Telespazio, Polish PIAP Space, and Ukrainian Paton.
Source: TASR
