Project Stellar Forge
Project Stellar Forge is an ambitious project initiated by the National Research and Development Corporation (NRDC) of Nouvelle Alexandrie in XV.1720 AN. The objective of this innovative initiative is to lay the groundwork for constructing robust, high-precision structures in space and on Tarsica, Micras' moon. The project breaks away from the traditional approach of building and testing space structures on the ground, instead focusing on developing structures like solar arrays, antennas, and optics specifically designed for the harsh realities of space or Tarsican environments.
Project Stellar Forge is currently in progress with a diverse team of industry and university researchers who are working to develop key proofs of concept in materials science, manufacturing, and design technologies. This will facilitate the production of future space structures on orbit, eliminating the volume constraints imposed by launch.
Objectives and Vision
Stellar Forge envisions ferrying raw materials from Micras and leveraging lunar materials for on-orbit manufacturing. It's important to note that the project does not involve building structures on the surface of Tarsica; all manufacturing is done in orbital construction facilities, and the results are utilized in orbital applications. Current New Alexandrian space systems are designed, built, and tested on Micras before being launched into a stable orbit and deployed to their final operational configuration. These constraints are particularly acute for large structures such as solar arrays, antennas, and optical systems, where size is critical to performance. Stellar Forge aims to enable a new paradigm where future structures supporting Nouvelle Alexandrie's space systems are built off-Micras using designs optimized for the space environment, shedding launch constraints. This will enhance capability, improve robustness, facilitate operations in higher orbits, and create potential for future cislunar applications.
Research Teams
A wide array of research teams are contracted to tackle a host of challenges related to two primary areas:
In-space Materials and Manufacturing
Teams tasked with this challenge include:
- University of Lausanne: They are developing new die-less fabrication processes to create orbital mechanical elements and bonded structures on-orbit.
- University of Cárdenas: They will develop predictive material and correlative process models to enable on-orbit use of laser forming.
- Institut des Sciences d'Amapola: Their focus is on developing a high precision in-space composite forming process utilizing self-energized frontal polymerization.
- Centre de Recherche Scientifique de Punta Santiago: They will develop continuous fabrication of regolith-derived, glass-ceramic mechanical structures for use in large-scale orbital applications.
- National Materials Laboratory: They will build a comprehensive materials properties database of additive-modified regolith for use in controlled thermal expansion precision orbital structures.
Mass-efficient Designs for In-space Manufacturing
Teams working on this aspect of the project include:
- University of Punta Santiago: They will explore new design approaches to mass-efficient, high- precision, stable and resilient space structures based on metamaterial and metadamping concepts.
- Laboratoire de Recherche et Développement de Chambéry: They will develop designs for extreme mass efficient large-scale structures optimized for resiliency and mobility.
- National Space Institute of Nouvelle Alexandrie: They will design novel tension and bending hybrid architectures and structural components with highly anisotropic mechanical response.
Phases of the Project
During Phase 1, the project performers are tasked to meet stringent structural efficiency targets supporting a megawatt-class solar array.
In Phase 2, the focus will be on increasing mass efficiency and demonstrating precision manufacturing for radio frequency (RF) reflectors.
In the final phase, the aim is to demonstrate precision for infrared (IR) reflectors.
Future Perspectives
Assuming current space technology trends continue, in 10-20 years we expect advances may enable Nouvelle Alexandrie to take full advantage of the Stellar Forge-developed technologies and capabilities. This includes robotic manipulation sufficient to enable assembly of large structures from Stellar Forge-manufactured components, enhanced on-orbit mobility, and routine re-fueling of on-orbit assets. We also anticipate several other advantages, including more affordable space access and launch costs in LMO (low-Micras orbit), GEO (geosynchronous orbit), cislunar space, and beyond.
