Abstract: A system and method for manufacturing a space-based component in space. The method includes collecting and capturing space debris directly from and suspended in space, heating the collected space debris using solar radiation in a manner that separately and independently melts different constituent elements and compounds in the space debris, collecting the different constituent elements and compounds as they are being separately melted, storing the elements and compounds in a molten, solid or vapor form, and fabricating the space-based component using the stored elements and compounds.

Abstract: A system and method for manufacturing a space-based component in space. The method includes collecting and capturing space debris directly from and suspended in space, heating the collected space debris using solar radiation in a manner that separately and independently melts different constituent elements and compounds in the space debris, collecting the different constituent elements and compounds as they are being separately melted, storing the elements and compounds in a molten, solid or vapor form, and fabricating the space-based component using the stored elements and compounds.

Abstract: A system and method for vaporizing space debris in space. The system includes a spacecraft body, a primary solar concentrator mounted to the spacecraft body that collects and focuses solar flux from the sun, and a secondary solar concentrator positioned at a focal point of the primary solar concentrator that refocuses the focused solar flux. A manipulator arm coupled to the spacecraft body grabs the space debris in space and positions it at a location where the refocused solar flux vaporizes the debris. The secondary solar concentrator can be a point-source concentrator, the primary solar concentrator can be a parabolic mirror, a Fresnel lens or a light focusing element or assembly, and the space debris can be a retired spacecraft or launch vehicle upper stage or component.

Abstract: A system for manufacturing a space-based component while on orbit around the Earth. The system includes a spacecraft body and a solar collection device mounted thereto for collecting solar energy from the sun that is converted into heat. The system includes a manipulator device that moves a solar refinery to a position to collect space debris, where the manipulator then moves the solar refinery to location that uses the heat to melt constituent elements in the debris. The solar refinery also includes a collection element capable of separately collecting the heated elements. The system also includes a fabrication module that is operable to obtain solid, molten or vaporized elements from the collection element and fabricate the space-based component therefrom.

Abstract: A spacecraft solar array structure including at least one sheet of amorphous silicon (12, 24, 34) formed on a flexible backing film, a supporting structure (14, 22, 36), and a mechanism for reducing the bulk of the solar array structure to facilitate storage for launch and deployment of the structure in space. One disclosed embodiment of the invention includes a sheet of solar array material that deploys as cylindrical array (12) that does not need to be mounted on gimbals. In another embodiment, the solar array (24) is disposed on a rear surface of an antenna dish (22). In yet another embodiment, the supporting structure of the solar array (34) includes multiple antenna dipole elements (36).

Abstract: A standardized interface between a spacecraft backbone structure (48) and multiple spacecraft modules (26) that are coupled to the backbone structure mechanically, electrically and optically. The interface structure includes power connection pins (42 or 50) that connect to a power bus in the backbone structure, data signal pins (44) that connect to a conventional data bus in the backbone structure, and an optical connection (46 or 56) that connects to an optical data bus (60) in the backbone structure. Optionally, the interface also includes a wireless data bus (54) using infrared propagation along the backbone structure, and a radio-frequency (RF) microstrip connector (52) for transmission of data at radio frequencies. The optical data connection employs an optical interface unit (62) in each spacecraft module (26) to convert optical signals from the optical data bus (60) to corresponding electrical signals, and a cross-point switch (74) to distribute the signals to appropriate destinations on the module.

Abstract: A compact spacecraft (10, 22) having a potentially long life in orbit as a result of its use of non-moving and solid-state components entirely or wherever possible. Amorphous silicon arrays (14, 24, 44) are used for solar energy collection. Because the arrays are not limited to a flat panel configuration, no movement is needed except for possible initial deployment. Phased arrays (12, 26) are used wherever possible for antenna arrays, in combination with torque rods (18, 3) for coarse attitude control of the spacecraft. Avionics modules (30, 50) are fabricated using large wafer-scale techniques and energy storage using long life battery or a solid-state capattery (52) technology. Propulsion is also effected with no moving parts, using waffle propulsion modules (20, 28, 54), which use elemental containers of propellant that is selectively ignited to supply propulsive force.

Abstract: A spacecraft (10) having a cryogenic cooler (24) that maintains different temperatures in thermally insulated and nested enclosures (26, 28, 12). In the coldest enclosure (26), which is maintained, for example, approximately 10.degree. K, low-temperature superconducting (LTS) processors (32, 34) perform bus and payload processing functions at very high speed. The next-coldest enclosure (28) is maintained at approximately 77.degree. K and houses high-temperature superconducting (HTS) electronic modules, such as for power regulation and distribution (40) and a payload sensor processing module (38). The third of the enclosures (12) is maintained at approximately 300.degree. K and houses other modules operating at room temperature, including a transponder (44), power control (46), energy storage (48), a propulsion subsystem (22), a downlink data processing module (49) and the cryogenic cooler (24) itself.

Abstract: A spacecraft structure using functionally independent modules assembled around a lightweight core structure to provide a vehicle that is lighter, uses less volume, and is easier to design, manufacture and test than a conventional spacecraft. In the disclosed embodiments, the modules are formed on generally flat panels, which serve as thermal radiators. The modules extend radially from the core structure and are attached to the core structure either in coplanar rows that extend axially along the core structure or in a coplanar set that extends circumferentially around the core structure. Interconnection between modules is achieved through a backbone interface, through which the modules are connected to the core structure. A large number of variant configurations may be implemented using the modular approach, by selecting a core, components and modules of number and size to meet mission requirements.

Abstract: A process for designing and producing spacecraft more efficiently, without the excessive time, complexity and expense usually associated with spacecraft design. The process moves the design complexity usually associated with spacecraft design to payload modules whose designs are potentially reusable in other spacecraft missions. Each module is designed to be largely independent of a parent spacecraft structure, the design of which can be simplified to accommodate multiple modules that connect to the parent structure through a standardized backbone interface. Each module is designed for independent structural integrity, and to provide its own thermal management. Modules may also provide their own power regulation and, optionally, their own power storage and generation capabilities. Modules may also provide their own attitude control systems. Attachment of modules to the parent structure is simplified because of the modules' independence.

Abstract: A spacecraft avionics module that is for the most part functionally independent of a core spacecraft structure, and provides its own structural integrity, thermal management and some level of power management. The illustrative embodiment of the module is formed as a flat panel that also serves as a thermal radiator. Electronic components are mounted directly onto the panel, which is normally attached by mounting hardware to the core spacecraft structure, through a backbone interface that provides data interconnection between modules and, in some cases, supplies unregulated power to the module. The module may include a power regulation function, or may also include power storage and power generation functions. For complete independence, the module may also include its own attitude control system.