Abstract

On-Orbit Manufacturing (OOM) presents a transformative paradigm in space mission design, enabling the in-situ production of components, tools, and large-scale structures beyond terrestrial constraints. This dissertation investigates the feasibility of OOM missions by developing a modular, iterative algorithm to support early-stage mission design and scenario analysis. The central hypothesis is that such an algorithm can be parameterised to evaluate a wide spectrum of manufacturing cases in space, ranging from small utility items to large structural systems.The research pursues four core objectives: assessing the terrestrial manufacturing lifecycle and its applicability in the space environment; identifying candidate manufacturing techniques suitable for orbital deployment; formulating top-level OOM mission scenarios adaptable across engineering breadth and depth; and developing a dedicated modelling tool, the On Orbit Manufacturing System Architecture Tool (OOMSAT), to integrate these analyses.The study addresses key knowledge gaps by bridging the domains of space mission architecture and advanced manufacturing processes, fields typically investigated in isolation. The novelty of this research lies in combining systems engineering principles with space manufacturing concepts to propose scalable frameworks for OOM mission design. The OOMSAT, implemented in MATLAB, automates parameter variation and iterative calculations that would otherwise be prohibitive if performed manually, thereby facilitating efficient scenario evaluation.Two case studies demonstrate the utility of the OOMSAT. The first explores the orbital manufacture of structural pipes, illustrating how conventional engineering products can be adapted to space-based production. The second examines a novel propulsion concept based on Quantised Inertia (QI), in collaboration with Dr. Mike McCulloch. This case study integrates experimental capacitor builds and testing with algorithmic modelling of Horizon Drive Capacitors (HDCs), demonstrating OOMSAT’s capacity to accommodate advanced and speculative products.The primary contribution of this dissertation is the creation of OOMSAT as a systems level tool to support feasibility studies, architectural trade-offs, and decision making in OOM mission planning. Beyond providing a structured methodology for evaluating orbital manufacturing concepts, the research establishes a foundation for future spacecraft engineers to refine, iterate, and expand upon. This work thus represents an early but critical step toward realising manufacturing as a core capability of future space exploration and infrastructure development.

Awarding Institution(s)

University of Plymouth

Supervisor

John Summerscales, Mike McCulloch, Jasper Graham-Jones

Keywords

SPACE, SPACECRAFT, Engineering, Quantized Inertia, QI

Document Type

Thesis

Publication Date

2026

Embargo Period

2026-06-09

Deposit Date

June 2026

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