OBJECTIVES:

Solving the space debris problem with a positive solution, recycling and manufacturing; done with the premise that it cascades into a more adaptable and sustainable global community.   The hope is that this project helps develop and deploy recycling and reuse technologies with the potential for commercialization in a terrestrial setting.

Codification:
NASA Classification: Space Operations Directorate.
Agency: SSPD Satellite Servicing Projects Division.
Oversight: IADC Inter-Agency Space Debris Coordination Committee.
Type: Orbital Infrastructure.

2020 Space Policy Directive 3: Space Situational Awareness and Traffic Management.

This project continues NASA’s current OSAM (Orbit Servicing, Assembly, and Manufacturing) initiative.  It is also a continuation of NASA’s FABLAB.  Consequently, this proposal is an ISRU (In-Situ Resource Utilization) project.

– – – – – – – – – – – – – – – – – – – 

Overview:

The proposal covers the entire scope of space recycling.  The first project is a stand-alone unmanned robotic drydock to handle satellite repair, servicing, disassembly,  construction, preliminary sorting, and cataloging space debris.  The industrial elements will fly in subsequent launches, which open the door for space recycling and manufacturing.  In addition to the station, there are specifications for a fleet of spaceships specialized in capturing and moving space junk.

Earth Policy in Space:  Yspace is dedicated to doing in space what we aim to do here on Earth. Protect the environment against climate change and reduce waste while continuing to mature and survive as a global community.  We are taking reusability and sustainability to a whole new level. Space…The final frontier for recycling.

The research in this project will benefit many terrestrial industries and help stimulate green technologies with a strong focus on recycling.  These developments would reinvigorate local manufacturing sectors, create jobs, create economic resilience, reduce waste for raw materials and manufactured goods, and reduce the need for international shipping.

Dangers of Space Junk: There are 750,000 pieces of space junk currently tracked.  Around 20,000 of those objects are more than 10cm long.  Contrary to popular belief, things naturally deorbit as there is some atmospheric drag.  The further you go into space, the lower the particle density of the atmosphere and the more time objects take to fall back to the planet.  Some objects in low Earth orbit will de-orbit within 20 years; however, most LEO objects take closer to 60.  Everything in space is traveling extremely fast.  The lower an object’s orbit, the faster it moves.  For instance, the ISS moves at 28000 km per hour, and the Hubble moves at 27300 km per hour in a slightly higher orbit.  Collisions at speeds this fast are catastrophic.  A pin can strike with the force of a stick of dynamite.  Every collision creates the possibility of several more collisions.  According to astrophysicist and former NASA scientist Donald Kessler,  If we reach a critical mass of space junk, the collisions can rapidly cascade, potentially destroying most active satellites and everything else in low Earth orbit within a short timeframe.

Capturing Space Debris:  There are specifications for every existing servicing or deorbiting spacecraft in this proposal, and plans for several more craft designed for specific roles.  Some are designed to move large rocket boosters efficiently. One type of salvage spacecraft is built on-site.  There are also current and future construction vehicles, some ideas for small debris collection, and other miscellaneous spacecraft.

Northrop Grumman’s MEV (Mission Extension Vehicle) is the first and most likely candidate for salvage operations.  It is currently the only operational service vehicle.  It has been tested and used in space on a few missions and works for this project.  Its limited design is built for one purpose.  It moves a satellite from one position to another position.  However, we have provided a wide array of potential spacecraft options for any situation.

Many of the salvage spacecraft mentioned in this proposal, including the MEV, use multi-directional ion thrusters, sometimes with a gimbal of 180 degrees.  The multi-directionality of the thrusters removes the need for traditional mono-propellants for relative proximity operations (RPO).  The thrusters use noble gases such as Xenon and Krypton for fuel instead of the more traditional hypergolic fuels.  While Ion thrusters have a low thrust value, their specific impulse allows for a five to ten times greater fuel efficiency. Otherwise, the refuel launch cost based on the rocket equation would make salvage operations economically unfeasible.

The space station design and launch plan are broken into two parts: The first element is the robotics servicing bay which can operate stand-alone. The second part of the plan focuses on the industrial elements of the station.

The Station:

The plan is to build the robotics bay from a salvaged rocket booster, preferably a Saturn 5 or IB second stage.  This “Drylab” ”Drydock” concept allows maximum workspace without a heavy and potentially unwieldy launch.  The plan is based on the early concepts of Skylab from Werner Von Braun, where a Saturn 5 rocket booster was to be converted into a human-occupied “wetlab.”  There is now an alternate plan to orbit the drydock with a heavy-lift rocket now that they exist again.

The servicing module features a bay door as seen on the space shuttle, a robotic arm for moving salvage into the work bay, and robotic workers such as JAXA’s GITAI or Boston Dynamics Atlas.  These right-stuff robots are equipped with several specialized workstations.  There is a workstation for cataloging inventory, a testing station, one for working with hazardous materials, one for cleaning paint and coatings removal, another for working with small things such as electronics, a heavy workstation, A finishing station, and standard assembly and disassembly workstations.

Powder, parts, and materials are transported around the station using pneumatic tubes and pods.  The pods are also used for storage.  There are several advantages to this sort of system.  It is easy to maintain, fast, reliable, and makes inventory easy to track.

The second part of the proposal focuses on the more industrial elements of the station, such as the recycling and manufacturing facility.  This facility can sort, grind, and smelt materials into powder feedstock for the additive manufacturing process using a 3D printer.

The current station specifications aim to reclaim or recycle 0.86 tons of materials in space per day.   Standard facilities on Earth recycle as much as 33,000 tons of material daily.  We are hoping to make a much more compact system. Some components could be blender-sized, toaster oven-sized, or Peppermill-sized with room to expand in the future.  0.86 tons would give a 100% or more return on investment within 20 years based on the cost per kilogram to launch. 

There are three types of recycling processes. Chemical, thermal, and mechanical. This project excludes the chemical process as it would be cost-prohibitive unless a closed-loop chemical cleaning process is worked out.  It uses the thermal process sparingly, as there is no convection cooling in a vacuum.  Instead, it focuses on the mechanical process.  Aluminum and Polymer (Plastic) are the cornerstones of our manufacturing process.   Aluminum and high quality plastics can be recycled using a strictly mechanical process involving shredding.   The basic idea is to grind down materials into powder and then use the powder as feedstock for a 3D-printed additive manufacturing process.

The Recycling Process: robotics bay: scan → clean → index → disassemble → sort.
Recycling plant:  shred → sort again → smelt → fine grind → manufacture.

What are we manufacturing?

.  We want to make specific components and spacecraft for servicing and recycling on-site and things we use in the process, including the ve transport pods, the in-house retrieval spacecraft, CubeSats, and other simple satellites.  We can build bigger and more complex things as we get better at the process.  Eventually, we will also be able to make advanced parts and materials for use back on earth, such as semiconductors.

Where In Space:  Most space junk is located in low Earth, sun-synchronous, counter-clockwise polar orbit.  The station should be positioned to run capture and salvage operations with the least fuel expended.  Initial simulations put the optimal position in a circular orbit somewhere near 85 degrees inclination with a 750km apogee and perigee. Alternatively, if this project is built in conjunction with the decommissioning of the ISS, it would be launched into an easy-to-reach equatorial orbit at around 500 km.

Finances:  The current estimate for the total cost of this project is around 29.6 billion dollars USD, plus or minus 50% based mostly on Human resources, over 20-year development and service time.  We plan to outsource to nearly 70 aerospace companies and employ around 5504 people.  Other than the basic idea of profiting from recycling one ton of material per day, there are several other potential sources of revenue, such as servicing, insurance, disposal contracts, and technology outsourcing.

Conclusion: This proposal covers the full spectrum of a space recycling and manufacturing process.  Parts are unfinished or lack enough specific detail.  It provides unique and innovative solutions.

End Of Synopsis

– – – – – – – – – – – – – – – – – – – 

Space Junk: 

(used with permission from ULA)

The Clean Orbits Initiative™: No, It isn’t really trademarked.  The concept is to reduce fuel and logistics costs for satellites, stations, and spacecraft due to less debris and lower the chance of collisions.  It will create a safer low-Earth environment and easier access to space.  It will bring down the costs of launches.

There is a direct link between climate change and space junk.  Currently, space debris in low Earth orbit takes between twenty and eighty years to naturally burn up in the atmosphere.  The problem is that CO2 gets trapped in the upper atmosphere while low Earth space loses density. The upper Atmosphere above 250 miles has lost 21% of its density since the industrial revolution.  If things continue, it will lose 80% of its atmosphere by 2100.  The effect is that debris in low Earth orbit will take much longer to de-orbit naturally.  –NY Times 5/14/2021

The upper atmosphere is one of two significant factors which cause natural de-orbiting.  Objects in orbit further out than 550 km are high enough that there is not enough particle matter to make any difference.   Satellites still slowly make their way back to Earth because of space weather generated by the sun.  It is known as solar “wind.” which isn’t wind at all.  It consists of light and thermal and ultraviolet radiation. Objects in low Earth orbit can take as long as 100 years to fall back into the atmosphere.  Anything higher than 800 km will take 100+ years.  Anything at a higher altitude will take so long to deorbit that it will likely see the end of humanity. –Space.com 6/22/2022

In addition to being a primary cause of natural de-orbiting, solar wind is one of the major hazards for operational satellites.  The radiation can cause electronics to fail.  In one instance.  SpaceX lost 40 out of 49 Satellites at once directly after launch.  They were put into safe mode.  However, after the storm. SpaceX was unable to turn them back on.  They all likely deorbited within a few days.   What happens when a solar storm destroys a bunch of satellites at once? – Scott Manley

Hazards aside, things still preserve better in space.  There is no rust, wind, or rain. There is gravity, but nowhere near the 22lbs per square inch or 9.8 m/s².   However, sunlight and temperature can impact pressurized components, often containing fuel and elaborate electrical systems.

Space junk is expensive because launch windows are shortened.  Calculations and logistics have to be made to prevent collisions.  Every launch has to have clearance from the USAFʼs 45th space wing.  The process is called a “COLA” (Collision Avoidance Launch Assessment). Less debris will help make their job easier.  If nothing else, it will free up some valuable time for some very smart people.

Space debris decreases satellites’ life expectancy by costing fuel to avoid collisions.  Satellites are launched with a limited fuel supply for orbital upkeep.  The more times a satellite has to slightly reposition itself to avoid a potential collision, the shorter its operational lifespan becomes.  Satellites are repositioned whenever the 43rd space wing predicts two objects in space will pass within 100m of each other.  It is guaranteed that we will get better at tracking space debris.  There are several new projects and companies dedicated to the task.   On the other hand, the amount of space junk is also increasing exponentially as more and more satellites are being launched, especially with constellation satellite projects such as Starlink or One Web.

We want to create a methodology for projects that simultaneously stimulate the environment and economy. Space junk is a serious hazard and demands to be taken more seriously. From an economic viewpoint, it is also the most expensive junk ever produced.  Thanks to recent research and development from DARPA, Grumman, Redwire, and several new startups, there might be a way to make a huge win out of a potentially catastrophic situation.  Forbes magazine created a list of what they think are the 50 most dangerous space junk objects. –Forbes

The main space polluters are the United States, Russia, and China.  Incidentally, they are the main polluting countries on Earth too.  According to Spacetrack.org, the Russian Government is the largest owner of space debris, with nearly 15,000 pieces.  Russia is followed by the United States government, with China in third place but coming up fast. – UK.RS online

Debris under 10cm constitutes a significant hazard.  Larger objects are easier to track and, therefore, easier to avoid.  All low-orbit debris travels at an orbital velocity of 7.8 Kilometers per second or 17,000mph.  Even a copper needle or a sliver of paint can collide with an active satellite station or craft with the force of a piece of dynamite.  Part of this project is a study on how to deal with space’s smallest problems.  For instance, metallic objects are easier to track and easier to salvage, even at smaller sizes. (see Catfish).

In addition to standard space debris, sometimes space debris is made on purpose.  Almost all active anti-satellite weapons currently are kinetic.  Development is changing as governments shift spending on alternative anti-satellite technology.  For now, it is the go-to weapon of choice.  They represent a serious threat and can generate large clouds of hard-to-salvage space debris.

(With permission from the Secure World Foundation)

Anti-Satellite Weaponry: China and Russia have recently invested large sums of money in anti-satellite technology.  The United States has recently created a new military branch.  It might not be a “space race,” but much research and money is dedicated to militarizing space.  It is a worrying trend that could make future space development much more difficult.  Unfortunately, kinetic anti-satellite weapons do not violate the 1967 outer space treaty banning weapons in space.

The first successful Anti-satellite weapons test was American.  An air-to-space missile (the ASM-135) was launched from a specialized F-15 in 1985.  Some of the debris remained in LEO until the year 2000.  America learned quickly as the collateral damage forced NASA to add thicker walls for the canceled Freedom space station.  The last Anti-Satellite test, Operation Burnt Frost, was conducted by the United States in 2008.  At 300km, the debris lasted around 18 months.  The United States canceled the project.

China tested its SC-19 ground-to-space missile in 2007.  It is described as a KKV (kinetic kill vehicle).  The test was unilaterally condemned worldwide as it created a massive debris field.  This debris field slowly expanded over several years and is just about everywhere.  There are still around 3000 tracked pieces of debris in orbit, with another 30000 smaller pieces still untracked.  It has created a massive headache for satellite and launch providers and is still a problem 15 years later.

India also conducted a successful Kinetic Anti-Satellite test in 2019 code-named Shakti.  Their Prithvi defense missile. It was successful.  After the incident in China, they hit the satellite from above and selected a target that was low enough not to leave any long-lasting debris.  However, they are expanding their anti-satellite weaponry to include weapons with less collateral damage, such as EMPs and directed energy weapons.

The Russians conducted a test in 2020 using the A-235 “Nudol” anti-satellite missile.  They had conducted Anti-Satellite tests in the past.  This one had immediate consequences.  The ISS had to do several expensive maneuvers to avoid a collision with one of the thousands of pieces of debris.  There were cosmonauts on board.  This test generated enough Ire from the international space community that it might prevent a similar mistake. Thankfully, for the time being, most space debris is not intentional. –Breaking Defense  

There was a recent hole in the International Space Station (2020). It was not caused by space junk.  However, space junk was the first assumption. One project element involves protecting our several billion-dollar investments or future several billion-dollar investments such as the ISS.  It does have several hundred dents from space debris. Fortunately, nothing has forced an evacuation or other catastrophic situation.

There was another incident with the ISS where a piece of small debris collided with the robotic arm.  Thankfully the robotic arm is made of rather heavy weight materials in space terms and could absorb the shock without serious damage.  If the debris had hit a different part of the station, it could have permanently disabled it or done serious damage. https://www.space.com/space-station-robot-arm-orbital-debris-strike

On March 13th, 2021, 2.9 tons of nickel-cadmium batteries were launched off the ISS with the intention of burning them up in the atmosphere in the next 2 – 4 years.  The batteries were still functional, but even if they were not, there is a good amount of material that could have been used for alloys in future projects in those batteries.  The battery packs represent  $7,888,000 of materials at the absolute lowest launch price of $2,720 per kilogram.

In February 2009, a collision occurred between a Russian spy satellite Cosmos 2251 and commercial communications satellite Iridium 33. It was a disaster that created potentially hazardous conditions for years to come.

In 2019 There was an incident involving a Capella Space satellite and another orbital object moving at 54,000 km per hour, nearly colliding and leaving a massive trail of debris. It was narrowly avoided with a slight orbital change.

The worst Space Junk incident by far occurred in 1978.  Soviet Cosmos 954, a maritime surveillance spy satellite, disintegrated on re-entry over Canada.  It was powered by a small, commonly used Nuclear Reactor called a Radioisotope Thermoelectric Generator(RTG).   When the Satellite disintegrated, it left a trail of radioactive waste over 124,000 square kilometers in the northwest territories of Alberta and Saskatchewan.  This greatly increased the cancer rates in an otherwise pristine corner of the Earth.

Space junk is an expensive problem today.  It could become exponentially more costly tomorrow if a critical mass point is reached where the junk collides and creates exponentially more junk.  As the cost of putting things into space comes down and more stuff is launched into Leo, the chances and the ensuing mess described as the Kessler syndrome go up. Currently, space debris costs one satellite per year.  Here is a statistic to drive the point closer to home; 5% of operational satellites are destroyed by space debris.

The movie Gravity (2013) illustrates the idea of the Kessler syndrome (Donald Kessler) as a modern space drama.  2 Russian satellites collide and then collide again into a Telstar satellite and further collide into the space shuttle while its crew is repairing the Hubble telescope.  After a few seconds, things are all colliding with each other.  It is a ridiculous overdramatization, but it drives the point home.  We can use some basic math to calculate the cost of space debris.  Satellite collisions are proportional to the square number of things in orbit.  You will get 100 times more collisions if you increase the amount of space debris by 10x.

Beyond the Kessler Syndrome, there are still sustainability metrics that need to be taken into account.  It is a term used in the space industry called orbital carrying capacity. The number of space objects in low Earth orbit can support before collisions become common. There is still a maximum saturation rate for space objects in low Earth orbit.  As you get closer to this saturation rate, more collisions will occur.  Some orbits are more widely used than others and will become problematic.  Those numbers are still vague but more accurate than calculating the flashpoint for Kessler-style annihilation.

Moriba Jah uses the term “orbital highways“  In response to why he is unconcerned with the Kessler syndrome but is concerned with space junk.  Those saturation rates apply to specific orbits, which are used often.

“I love it because it’s trash.” – Oscar, the Grouch.

– – – – – – – – – – – – – – – – – – – 

Servicing and Construction Opportunities:

Satellite repair is a thing now, but the heavy price tag doesnʼt make it as feasible as it should be. Providing a base of operations for these projects could reduce the servicing craft cost in LEO. The robotics bay provides a safe and enclosed environment to perform these repairs. It provides a high-tech industrial laboratory to test and perfect new technologies in space. It provides a safe staging point for industrial robots. It includes space for storage. It offers essential refueling services for satellites.  It greatly increases the scope of possible repairs and allows for in-orbit assembly. (See mission 1)

There weren’t many service missions before the ISS.  You could count the American missions on your fingers.  The first was the repair of a solar panel and heat shield on Skylab in 1973. The next mission was STS-41C in 1980, where the crew performed EVAs to fix the Solar Maximum satellite.  It was done using an astronaut mounted at the end of a  robotic arm in the space shuttle’s payload bay.

The following two were both done on  STS-51A in 1984.  The astronauts used free-floating jetpacks (MMU) to retrieve and repair the Westar 6 and Palapa B2 Satellites.  The next servicing missions were the epic Hubble repair and upgrade missions during the ’90s.  It included STS-61 and four other servicing missions.  We got better at it, for sure.  The most advanced servicing missions are, of course, the construction of the ISS.  It required 40 launches to build the ISS, including 36 space shuttle launches and over 200 spacewalks.

Spacewalks:  Spacewalks are how we do construction and maintenance in space currently. CanadaArm and Dextre can do some tasks, but most things are done with a human hand.  There is that comforting feeling that we are living in the future.  It is just like that ride at Epcot center showed us.  Spacewalking is difficult, heroic, and extraordinary. However, It is not the best way to do things.  

Here are some drawbacks to crewed extravehicular activities, as opposed to robotic extravehicular activities. There is a 2-hour preparation time to suit up and another hour for unsuiting and depressurization. The procedure is complicated and necessitates additional astronauts during prep time.  The process requires a dedicated airlock for (de)pressurization. Once the astronaut(s) are suited up, they have a limited duration for spacewalks with several factors involved. Ten hours is the maximum time an astronaut can go on a spacewalk.  We have come a long way.  Our space walking technology has improved.  Our suits have gotten better.  However, there is still a serious risk to human life and a significant monetary cost. 

Astronauts are subject to miscommunication.  We have established precedents in what they say and how they talk to prevent this, but it is still a hindrance.  Even though we have made progress with the spacesuits, they still come up short in a few ways. They have almost no peripheral vision. The suit prevents astronauts from turning their heads at all. The current makeshift solution is to attach mirrors on the wrists of the spacesuit so that they can get at least some vision.  Furthermore, the spacesuit gloves make the astronauts suffer from a lack of dexterity.  Robots have the full spectrum of movement and can apply force with greater accuracy using tools such as the PGT – Pistol Grip Tool (Screwdriver).  The last problem with human spacewalks is the price points associated with keeping meat bags warm and oxidized during the spacewalk. Spacesuits break which makes them dangerous.  It is costly compared to a robot.

There are issues with using robots for construction and repair too.  Nothing is perfect.  There is a short delay in communications for robotic instructions.  Meatbags can think on the fly.  This can be countered by controlling the robots from a space location with humans.  Astronauts can sense a problem, whereas robots have no sense of touch or basic understanding of the problem.  Robots have peripheral vision but don’t automatically come with situational awareness.  Lastly, robots take orders perfectly but do not think.  They will have to be trained and developed over time.

Some of the best service opportunities involve stand-alone spacecraft.  There have been several servicing spacecraft proposals.  Nasa has a whole section devoted to the process called OSAM.  The first SSPD spacecraft to be launched was the Northrop Grumman MEV-1.  It is a basic spacecraft that fulfills one role.  It attaches to satellites in geostationary orbit and repositions them after they have expended all of their fuel.  It is a one-trick pony but works exceptionally well.  The subsequent robotic Satellite servicer up to bat is Restore-L, now designated OSAM-1.  It will launch in 2025.  We will see how effective it is.  Another development is Lockheed Martin’s GPS III satellites.  They were designed to be upgraded, serviced, and repaired in space from the ground up.

Advantages of On-Site Satellite Servicing: One major flaw with this proposal is the need to recover, repair, and re-orbit Satellites.  We are competing with proposals that can service satellites while not bound to a central location.  They use much less fuel and do not require a robotics bay.  However, we offer the ability to refuel and retool servicer craft as well.

Mostly Dead but not Completely Dead:  Why did we go over the pros and cons of spacewalks in such detail?  Satellites are generally not made to be serviced.  Most of what has already been launched would require a drydock for servicing, assembly, and disassembly within a safe and enclosed space.  It would be similar to the space shuttle bay but much larger.

See mission 1 for exact details.

Disaster Mitigation:  The recycling salvage restoration ecosystem creates opportunities when something goes wrong.  It can mitigate disasters in the near and long term.  It could help seal that Oxygen leak on the ISS Zvezda module. It could help repair a heat shield on a space shuttle or capsule.  It can move a piece of space debris before it collides.  In countless other circumstances, it provides the ability to assist when disaster strikes.

Science Opportunities:

Yspace is focused on Recycling and Manufacturing.  They are technologies that will have a major impact on humanity.  That said, we strongly support projects like the James Webb Space Telescope and other space endeavors which attempt to answer the biggest Y questions.  How was the universe made?  What is the shape of the universe?  What is causing its rapid expansion?  Is the Universe  Infinite?  What is the universe expanding into?  Are we alone?  Have humans been to space before the 20th century?  Perhaps our drydock experiment can help speed up the process of getting answers.  While the project is engineering specific, it is not science-averse.

Earth’s Formation: We can learn something about the creation of the Earth and perhaps the early history of our solar system and Earth’s primordial history by investigating and capturing, and studying NEOʼs – near-Earth objects that are not human-made space junk.

We would be able to collect and analyze “Stardust” from the surfaces of objects that have been in space for some time.  This could potentially provide fantastic insight into the origins of our universe.

Ancient Aliens: It is every conspiracist’s favorite go-to theory. It is doubtful that ancient civilizations went into space, but if they did, there is a chance we could find some old human space debris with a project like this. Maybe a NEO in LEO or a mystery Canopic jar filled with acid or braains in space. How much would discovering an ancient or alien civilization’s space junk be worth? (At least a tv mini-series).   Are there alien artifacts orbiting Earth?  Dr. Beatriz Villarroel examines two transient objects in geosynchronous orbit from 1950, seven years before Sputnik.

Materials Sciences:  There are several opportunities to learn about the Interaction of and manufacture of materials and compounds in a zero-gravity vacuum environment.  One example would be a comprehensive study on the forging of metals without oxygen content using electrolysis. Another example is a system for harvesting and separating gases in a vacuum.  Without gravity, Things can be stirred, and they won’t separate. It allows for otherwise impossible chemistry and self-organizing structures. One factor is the lack of convection. Heat moves slowly through materials.

Zero gravity oxygenless space manufacturing creates the ability to make super materials such as Semiconductors and Zblan, or quartz crystals grown in space.   Further investment into this project might reveal new and interesting super materials.

We would better understand liquid dynamics in zero gravity and how to work with the many odd properties of liquids in space.  One bizarre element of liquid with no gravity is its tendency to ball up.  It is something we hope to exploit when making feedstock for 3D printers.

Engineering Opportunities:

This is the megaproject that the world needs.  It could potentially revolutionize the modern manufacturing industry and bring back localized small-business manufacturing.  This project provides countless opportunities to further our understanding of space construction and repair.

This project will create breakthroughs in space robotics and manufacturing.
This project would be the first to launch heavy machinery and or construction equipment into space.
This project creates the ability to expedite project development timelines for high-priority concerns and objectives and extend the life cycle of existing hardware nearly indefinitely.

One major challenge of the project is sorting.   We need the ability to sort materials from scrap better for this to work.  We hope to do this on a molecular level or as close as we can, in zero-g and autonomously.   This would have a big impact on Earth recycling projects as well.

Space sustainability: When we go to the moon or Mars for an extended duration, this project will help develop and miniaturize the technology required to mine and reuse fuels, necessities, and materials properly. When we go further, this project will help with transit craft repairs where limited resources are available.

Some Assembly Required:  The ability to do basic assembly in space allows for larger objects than any fairings currently can support.  We do not have to “deploy” anything.   We can build without the traditional origami required to fit into a faring.

Cylindrical Space: Is everyone sick of cylinders yet?  Let’s break out of the circle! The remanufacturing process will allow designers and engineers to build things in space that do not have to fit in a rocket payload and pursue other design objectives without having to create a new launch vehicle.

Everything launched into space has to make design concessions to factor in the rather severe vibrations associated with space launch.  Objects produced in space would not have to adhere to these design constraints.

The semi-violent nature of rocket launches.  Oftentimes, when things are launched into space, things break.  There is a lot of vibration as well as a high G-force.  The latest example happened in October 2021 when the Lucy Space probe failed to fully deploy one of its solar panels.   The construction of things in space allows for greater flexibility in what is being constructed.   We can use less durable materials.

The project would allow engineers to design without having to factor in demisability. (The ability of a satellite to break up safely in orbit).  The lack of breakups enables future engineers to use iron, steel, and other harder materials in future satellite and spacecraft designs.

The lack of gravity in space allows for building structures that do not need to resist gravity.  One would imagine that we could make some extraordinary structures if you don’t have to factor in the 20 pounds per square inch that everything and everyone has to work against since the dawn of life itself.

The Future: It would function as an industrial space kick starter for several essential technologies that easily translate into other projects.  It would provide insight into future missions on asteroids such as Psyche or celestial bodies such as the moon or Mars, Phobos, Deimos, or wherever in the solar system works best.

This project would give us a better understanding of thermodynamics and heat exchange in a vacuum.  The station will need massive heat dispersion via radiation.

STEM Education Opportunities:  (Science, Technology, Engineering, and Math)  

A wonderful thing about engineering megaprojects is their ability to inspire.  We think a project like this could potentially inspire the entire world.  Perhaps it would create an engineering renaissance.  Something like this is what the new generation needs to pursue a serious interest in math and science.

We want to tap into the creativity and imagination of the younger generation.  Yspace hopes to inspire enough that it gets engineering into every high school curriculum across the United States.

Space Defense Opportunities: 

War: Someday, two or more spacefaring nations will go to war, hopefully a long time from now. We have learned at least one important lesson from the recent Chinese anti-satellite weapons test.  Almost any sizable military action in space would have a fair chance of cascading collisions.  These impacts would eventually trigger the Kessler effect, rendering parts of low Earth orbit unusable for several years. The Chinese anti-satellite test proved that it is safer to de-orbit, take control of, or recycle the enemyʼs space assets than to destroy them.

The war will likely involve a superpower aggressor and a rocket-capable underdog.  Let us use Russia vs. Ukraine as an example. Had the United States and its allies intervened on Russiaʼs behalf, Ukraine would have had nothing to lose by launching a box of firecrackers and 4+ metric tons of Iron filings.  It would destroy most things in low Earth orbit and prevent any launches for several years. Building the station and cleaning up space before it happens would prevent a horrible situation before it begins. After the war, provided humanity isnʼt destroyed in a nuclear apocalypse, it becomes a force-move. The project will have to happen in some form or another. It would be much harder with infinitely more objects of smaller sizes and complex orbits. The project goes from fun, inspiring, and profitable to completely necessary, slightly humiliating, and massively expensive, as the pieces would be much smaller and harder to capture and recycle.

There was a study published around 2006 in I-Tass (Russian Newspaper). It outlines the leading cause of future conflicts. It says the next several wars will likely be fought over resources like water, gas and oil, and even food, as the demand for essential goods goes up with the increase in population, but the supply goes down due to factors like global warming. The proposal will hopefully partially mitigate future problems. If nothing else, it will tell our allies that we are concerned and trying to help. The best way to win a war is not to fight it. (ancient Chinese proverb).

A study from MIT in 1996 Titled “The End is Near!”  calculates that at the current consumption rate, several necessary resources will be depleted within 60 years (More than 25 years ago).  This plan would reduce our foreign reliance on raw materials, rare Earth metals, and fossil fuel while increasing our manufacturing capability.  In turn, it would allow the country to reduce its business dealings with countries that have unstable or oppressive governments.  Recycling reduces our reliance on foreign assets like oil and rare Earth minerals.  Waste to power reduces our dependence on gas, coal, and Oil.  Why a recycling plant?  Why a recycling plant in space? Because humanity is the biggest threat to humanity.

Space Force:  One of the main objectives of The United States Space Force is to safeguard American military and commercial assets.  It might mean a sequel to the original Star Wars project.  Remember that anti-ballistic missile laser in space from the 80s?  This project does not directly protect anything from intentional destruction or sabotage. However, It can mitigate some damage from said destruction  RSVʼs can function as offensive weapons allowing for sabotage and control.  It can also be used to safely de-orbit enemy space assets.  There is no reason to Blow up a satellite with a rocket.  It is dangerous and stupid.  Perhaps RSVs will end up in the first space dogfight.  It would resemble the show Battle Bots, where the robots viciously try and rip each other to pieces (without projectiles).  In peace times, the primary threat is an accidental collision. This project mitigates the danger from debris more than anything else proposed.  The planet needs protection from events like the 1978 Soviet Cosmos 954 incident.  Radioactive debris presents  a clear and present “space threat.”

Unfortunately, because of the war in Ukraine, Space Force has had to change its priorities.   Had Russia not escalated the war,  Space Force would have been able to contribute more assets toward this project.

The Navy: The USS Jimmy Carter, The Parche, and the Halibut submarines were designed and augmented to do underwater servicing and sabotage missions.  The majority are still classified.  The Parche and its successor the USS Jimmy Carter are both 100 feet longer than other submarines of their respective classes and outfitted with few deadly weapons. One of the more famous activities of these engineering based submarines was the tapping of Soviet and Chinese undersea communication cables.    The Carter is nearly 130 meters long and has a Nuclear reactor, but doesn’t have any nuclear missiles.  They all featured unmanned underwater service and scout vehicles. These and other classified missions might represent the best of what we can currently do for servicing in space.  

The Navy refers to RSVs (Remote servicing vehicles as ROVs (remotely operated vehicles).   Several of the same vehicles are used in offshore oil rig construction, dam, dykes and breakwaters, bridge and tunnel construction, offshore wind farm construction, repairing undersea power and communications cables, pier construction, and restoration.  The Carter is the most recent build. For salvage, the Carter uses the Deep drone 8000 and the MR2 Hydros.  They both feature hooks, cable, thrusters, a diesel generator, gyro stabilizers, cameras sonar, and hydraulics. 

From a wide-view perspective.  The project would immediately involve increased funding for engineering enlistment on an officer level from Annapolis to bolster our naval capacity for undersea construction sabotage and surveillance.  The information gained would directly increase the capacity for Space Force and NASA’s servicing projects division to accurately conduct similar space operations.  The endgame for this hefty endeavor is space construction.

The Army: R-fab is a 3-D printer used by the US military to print stainless steel tank parts on the battlefield.   It has been tested and proven to work.   While there is not as much stainless steel in space as Aluminum, the result is the same.  We create parts as needed.  Our salvage operation minimizes raw materials shipping costs to a very hostile environment (space).  Potentially reducing those shipping costs to zero.

The Forgotten Nuclear Arsenal:  Between the United States and the Soviets, we’ve put several tons of the nastiest things on the periodic table into space. It would be another catastrophe if some of these things deorbited and spread a radioactive gas cloud over several thousand miles.  With the lower cost to orbit, it would also be bad for a small, potentially hostile country to acquire weapons-grade nuclear material from a source in low Earth orbit. Perhaps we can boost some of the waste material to a higher orbit. Still, there is always a chance that potentially hostile entities could grab it from further and further trajectories as technology improves. Alternatively, although a bit riskier, we could return hazardous waste to Earth using heat Shields for secure disposal and storage on the planet.  We might be able to facilitate launching nuclear waste toward the sun. However, the maneuver requires about 33km/s delta-V, which is fuel prohibitive for chemical rockets.  A better solution would be to use an ion drive, although It would take several years to build up the velocity with even a small payload.  That leaves only one good solution, which is to use it for power and or propulsion.  Once it is expended, It is not valuable enough to get it from space.  Heck, anyone can go pick up some depleted radioactive material with a backhoe 30 miles in any direction from Las Vegas (I live in Las Vegas).  Scary but not scary like the weapons-grade stuff in space.

Life in War Times:    War increases the rate of global warming, which is bad.  However, an escalation into a full-scale nuclear war and winter would abruptly end global warming and kill off most of the human population, with a 100% kill rate for everyone north of the equator.   If that happens, well?   There will be no need for space for anything.

Asteroid Mining Opportunities: 

It has been said that 100t of Rhodium is worth 47 billion dollars.  It is a slightly flawed argument for Asteroid mining.  It would cost an “astronomical” amount of fuel to provide the delta-v necessary for returning 100t of any rare Earth metal from Psyche back to Earth orbit.  Even more so to get it to the ground.  Yes, some of the asteroid can be converted into fuel.  Especially with C-Type (carbonaceous) or S-Type (silicaceous) rocks.  However, most times, there isn’t enough asteroid to create enough fuel to provide the amount of delta-v necessary for its voyage back into low Earth orbit.

Building a factory in space might be cheaper.  But what would we do with Rhodium in a space factory?  Aluminum might be more valuable per kilogram for space manufacturing.   There isn’t 100t of rhodium in low Earth orbit.  However, we did use a significant quantity of other rare Earth metals in our numerous space projects in LEO and an astonishing amount of Aluminum.  Even CubeSats use a good deal of gold.  A space recycling project is a cheaper and more realistic solution.

NASA has located more than 27,000 Near Earth Objects.  It would sense that there would be asteroids in Earth’s orbit.  There is a moon, so we know it can happen.  There are billions of asteroids in the solar system.  Surely one would come in at just the right angle to get trapped by the Earth, or a rock hits the moon, and the ricochet shoots debris out into space which could then get trapped in orbit around the Earth.  Unfortunately, that doesn’t seem to be the way it works.  There are no asteroids that we know about in Earth’s orbit.  Frankly, it is a little weird.  Until we find one that is, or find an M-class (metallic) that comes very close to Earth with enough time to intercept, asteroid mining isn’t worthwhile.

Asteroid Redirection:  Asteroids usually move exceptionally fast and have the unfortunate habit of generally weighing several hundred tons or more. If an asteroid were detected early enough, this station can refit engines and make necessary changes to a customized craft with enough thrust for the job.  Space tug boats are required to move most rocket boosters and are uniquely equipped to prevent this sort of disaster.  There is a chance that some of the more expensive and modern service vehicles we intend on using, like Restore-L (with Ion Thrusters), can get the job partly done without refitting.  However, there are a few suggestions later in the proposal that would do the job much better.  In October 2021, NASA launched the DART double asteroid redirection test.  It uses a kinetic impactor to change the orbit of the asteroid Didymos-B, which is 163 meters by a slight amount.

Environmental opportunities:

(moved to bottom)

Terrestrial Opportunities:  

(moved to bottom)

– – – – – – – – – – – – – – – – – – – 

Cross Project Compatibility:

 Part of the beauty of this project is how open-ended it is. It will assist almost any other project. It does more than just deal with the space junk problem.  The Moon? Mars? This will help.  For asteroid mining, this would be an essential step. Communication satellites for faster internet need to be serviced and refueled. Even secret star wars weapons and surveillance need repair.  How about a new wing for the space hotel? Can we build lunar construction equipment?  The project can provide assistance whatever we do next, whenever, and wherever we do it.  This project is fundamental for the space ecosystem and a practical road to the proper fulfillment of ISRU.

Pre-launch Opportunities:  

Yspace Aerospace Manufacturing:  Long before launching anything into orbit, we must design and test facilities on the ground.  Since the facilities in question happen to be a factory to manufacture space components, it would make sense to build a similar facility on the ground, less optimized for space, in favor of efficiency.  It would allow us to “train up” our skills in using recycled material in the additive manufacturing process to build precision components.  We would not be the first company to use additive manufacturing in aerospace.  Both firefly and relativity space are highly invested.  However, our end goals would be different.  Perhaps our facilities can be conveniently located near a small airport and pick-a-part automobile scrap yard.  It would allow us ample material to experiment with and a client to service, as well as the ability to ship parts to other small airports easily. 

We aren’t tearing down any museum exhibits (but we would not mind a space shuttle), landmarks, or statues. However, it might be a good project for picking through the airplane boneyard in Palmdale, California, or enlisting the aid of the 309th Aerospace Maintenance and Regeneration Group at Davis–Monthan air force base in Tucson, Arizona.  It is the largest aircraft boneyard in the country.  Alternatively, A good amount of salvage can also be used from the U.S. Navy.  Some essential components cannot be made from recycled materials.  Everything that can be should be. Sometimes the knowledge gained from the process is more valuable than cost savings. 

In order to test the robotics bay, it would be fun to try and restore small prop planes remotely using robotics in an enclosed environment built for the purpose.  Robotic repair and disassembly is our first objective in a long line of objectives.

Constructing Ground Facilities:  The research and operations facility could be about the size of a car dealership, with extra high ceilings, a Central area, and two floors of offices surrounding the central area. After the design and testing are done, space could be converted into mission control, where day-to-day operations of the factory station and retrieval craft are carried out. 

– – – – – – – – – – – – – – – – – – – 

Space Debris Database (SDD):

We need to expand and augment the current space debris database with much more information.  We already know the apoapsis and periapsis of every known space debris object.  However, we need specific information.  We need to know the size and weight.  We need a parts inventory.  We need to know if there is fuel remaining and the state of the fuel.  We need to know the reason for its demise.  We must document potential hazards such as leaking battery acid, potentially explosive, radioactive, and such.  We need to know if any Oxygen is converted from liquid to gas or solid that could rupture but also has a high salvage value.  We also need the salvage Delta-V requirements based on the station’s position in relation to the object in question and the craft involved in the salvage.

Spaceforce currently tracks only 32,000 objects of the 1.4 million pieces of space debris.  Most objects are just too small. (citation needed)

In March 2021:  The US Space Force agreed with the database pre-launch study.  They likely need the data for other things.  Either way, it’s happening and with a massive $280,000,000.00 budget.  The contract to build out the space debris database is being fulfilled by a private company called Bluestaqs. – Spacenews

As of  September 2021, there is a second plan to map space junk by a new company called. Privateer.  They are being supported by the legendary Steve Wozniak, the co-founder of Apple computers.  They have recruited space junk expert Moriba Jah.  Moriba and UT Austin have built a great tool for tracking space junk.  Privateer is launching its Pono Spacecraft next year. – Privateer

Satellite Salvage Mission Quicklist: 

Salvage or on-site restoration: S/O
Recovery craft: (type)
Cost of project: (num)
Current orbit: (A=num) (P=num) (Inc=num) (E=num)
Amount of fuel required for salvage: (num)
Current ownership: (char)
Tonnage of salvaged debris: (Num) 
Aluminum % of material content: (Num 1-99%)
Plastic % of material content:  (Num 1-99%)
Precious metals % of material content:  (Num 1-99%)
Carbon fiber % Content: (Num 1-99%)
Non-recyclable elements:  
Fuel Type:  (char)
Remaining fuel? Yes/no:: how much? (num)
Frozen fuel? yes/no
Leaking fuel? yes/no
Monopropellant? :: Yes/no :: how much?
Solar panels? yes/no 
Working batteries? yes/no
Nuclear components. yes/no 
Radioactive: yes/no 
Intact: yes/no
Debris field: yes/no

Station Position: 

The station needs a position. There is an initial starting orbit laid out in the following missions. However, the station’s position should be in a location that allows for the maximum salvage potential while using minimum delta-V.  Fuel is the most significant expense for the project and the best salvage payoff. The two perspective positions are a counterclockwise equatorial orbit, making the station easy to rendezvous with.  The second option is a  counterclockwise sun-synchronous orbit, which has access to solar power 24/7.

The ISS is around 400 km up with an inclination of 51.6 degrees.  However, most space junk is around 600-800 km in a sun-synchronous orbit at around 80-90 degrees.  Our two position options.   Changing inclinations by that much would cost a fortune in fuel.  The station is designed to be able to service and recycle large components, but the fuel cost for a 30-degree inclination change is extravagant.   I was able to move the recycling station in Kerbal by 48 degrees.  However, the ship I built to make the move was ridiculous.  It used 60 ion thrusters, weighed nearly 50 tons, and used most of its fuel for one move.   It leaves the project with two options.   One is an equatorial orbit similar to the ISS.  This orbit does not provide sunlight 24/7 and would require more batteries or perhaps an alternative power source (such as the Krusty Nuclear power reactor made for space).

There is plenty of space junk in an equatorial orbit, but the big debris field is in that aforementioned sun-sync orbit.  Perhaps the best option is to do it exactly as I did, recycle the ISS and then pay a massive amount of money for a very large inclination change once.  It depends on the timeline.  If the ISS has another 20 years in her, the best option might be to do the reverse.  Unfortunately, this station and the ISS are too massive even for the highly capable space tug outlined in this project for such a degree of orbital inclination.

The going figures from a first foray on the internet put the average fuel cost at 1% of delta-v for every degree of inclination change.  Delta-v is how many meters per second change the amount of fuel in the tank can get. There are 360 degrees in a circle, but, for the most part, we are only dealing with 90.  There are not many spacecraft going counterclockwise. Which removes 180 degrees.  We are operating in a + polar orbit, as that is where most of the debris is.  Ion Thrusters will get a 5x multiplier which is pretty serious.  Technically I should have been able to move that 350-ton station for 3% -5% of its fuel rather than the 220% it took.   Even with hypergolics, it should have only taken 19%. My experiments in kerbal were significantly worse than that by a factor of at least 4x.

– – – – – – – – – – – – – – – – – – – 

Financial Opportunities and Concerns:

It is not just about doing the right thing. This project is a business venture.  It will be sustainable as a profitable, long-term endeavor.  It doesnʼt just make sense.  It will make dollars too.  Older satellites will be reconditioned. This process would likely produce a decent return fastest and generate some funding for phase 2.  Disposal contracts will be made with the original owners of said space junk.  We will restore satellites to a functional condition for a fraction of the initial cost.  We will have a contained, dynamic, and adaptable platform to work from.  As we switch into phase 2, it is important to realize how much “space junk” is worth.  Space cans are worth much more than 5 cents and might not be as hard as one would think to restore/recycle/reuse.

There is a common phrase in the space industry, usually associated with asteroid mining. “‘Creating a space gold rush.”  There is a problem with the idea.  There needs to be manufacturing and processing in space, and we do not currently have the facilities and infrastructure to do so.  This project serves as the cornerstone for any future profitable space endeavor.  It is possible to do this with current or even slightly obsolete technology.  It also fulfills the secondary phase of establishing ISRU (In Sitro Resource Utilization) and the beginning of space manufacturing.

Good News! The project will not require a new launch vehicle. It can be done with existing rockets. The station is unmanned and in low Earth orbit, making it feasible and safe. It is robotic in origin and should only require unmanned launches for construction. This project champions innovation in engineering, which will benefit the United States and its allies and partners.

The Free Press:  The good nature of this project would make and hold headline news, generating positive free press, which could be leveraged for continued funding.

Cool Beans:  The project, if done right, might even have a positive ROI (Return On Investment). Space manufacturing, repair, and recycling might have the potential to be the most profitable space project yet.  The project fills several roles in military, government, and commercial sectors.  It accomplishes long-term results cheaper than alternatives or stand-alone missions.

The first segment of this project, the robotic service bay, is compatible with NASAʼs FABLAB.  The service bay can be easily incorporated into Lop-G, the ISS, Orbital Reef, or any other space station in the works (see mission 1).

This project continues NASA’s current OSAM (Orbit Servicing, Assembly, and Manufacturing) initiative.  The proposal is an ISRU (In-Situ Resource Utilization) project.  It can help with our moon and Mars objectives by providing infrastructure, technology, logistics, maintenance, manufacturing, construction, and refueling services.

The concept of a graveyard orbit dates back to 1977. However, in 1997, it became an official recommendation from the IADC (Interagency Space Debris Coordination Committee). Most satellites positioned in geostationary orbit are specified to move out to the graveyard orbit, which is 35,786 km from the Earth.  It is possible to make our station the new “graveyard orbit” for low Earth orbit, with a mandatory disposal contract required for launch. Suppose the station was the final destination for satellites and other end-of-life space projects.  Then there would be a constant flow of business.  This presents the opportunity for fuel-free salvage.  IADC Guidelines.

The second opportunity for fuel-free salvage comes from intentionally de-orbited or landed rocket boosters.  In order to prevent future hazards, the modern space industry does their best to ensure that their boosters, batteries, and other components don’t become part of the problem.  They make sure there is enough fuel left to properly de-orbit their boosters.  This project would allow launch elements to be used in future space projects.

While several De-orbiting projects are in the works, recycling is advantageous instead of de-orbiting. There are 7600+ estimated metric tons of human-made space junk currently available for salvage, provided we can get permission from said entities.  Space junk tonnage will go up as the price per launch decreases. The same tech that will enable us to make this station for a reasonable price will also make this station necessary. Of the 750,000 pieces of space junk that we have located.  There are more than 6500 Satellites and 2000 rocket casings that are not functioning and are available for this project.  There are more than 20,000 objects more than 10cm long as of January 2021.  70% of space junk by weight is rocket boosters.  These numbers are likely to grow exponentially.  Space debris by the numbers

The number of satellites will increase fivefold or more in the next 20 years. This uptick will ensure the future profitability and function of the station.  Nothing prevents us from launching powdered material and specialized parts from Earth to supplement construction and assembly projects.  In 2012 there were 50 small satellites launched into space. By 2025 there will be over 1000 small satellites or more per year launched into space.  The ongoing estimate is that satellites in low Earth orbit will grow by 1000% in the next ten years. There is a nearly endless supply of future space junk to salvage. Historical growth of space debris.

Starlink:  Recently, SpaceX came up with a novel idea called Starlink.  The system uses thousands of CubeSats to provide high-speed worldwide internet, any place, any time.  They have single-handedly doubled the number of satellites in low Earth orbit.   It is a great system, but there are drawbacks.  Some of the CubeSats are dead on arrival, some fail, and of course, they all have a life expectancy.  There is some good news.  Most low-Earth CubeSats will fall back into the atmosphere from 20 to 60 years after running out of fuel.  However, this is still a significant space junk problem.  The world noticed that it was not very hard for SpaceX to launch the Starlink system.  There will be many  ‘cubeswarms’  and new Starlink Competitors in the future.  These CubeSats are all equipped with tiny ion thrusters and have a low mass.

Starlink 2.0 Servicing  Starlink 2.0 Satellites are significantly bigger and more complex than Starlink 1 CubeSats.  They are so big that they will require a starship to launch but are still in low Earth orbit.  Their increased value could potentially mean a more profitable satellite service contract.  SpaceX intends to have 42,000 satellites in its constellation.

There are several more satellite constellation swarms in the works.  HughesNet filed for 1440 Cubesats  Inmararsat filed for 198. Telesat filed for 1671.  ASTScience filed for 243. Mangata filed for 791.  Boeing filed for 147.  And Astra filed for 13,620 CubeSats.  One Web, now owned by Bharti Global, has already launched 358 and plans on launching many more.  Satellite Filings

Everything up in space belongs to an entity. But oftentimes, indeed, most times, it is not an asset to the said entity. It is a liability. If said junk collides with anything, the owner is responsible. If we securely dispose of the debris, they are no longer liable.  There is a negative factor.  The minute we build this project, perhaps even before it even goes up, the minute we assign a positive value to space junk, it will retain that value to its original owner.  In other words, the debris is worthless until we build this, but after we make this, that same junk has worth, and the owning entity will likely want compensation.

Ownership presents a legal hurdle in the negotiation of salvage contracts. Including international partners early on could make those contracts easier to sort out.  Some say international collaboration in space is dead with the rise of private industry and political instability, and indeed, this could be built by a single nation or private company. However, part of the ISSʼs success was that several mutual multinational commitments needed to be honored. The project will be expensive and will continue for many years.  It might require a good deal more initial capital than most single entities can provide.

While space is mostly considered international waters, the value of space real estate is much higher in Geo-Stationary orbit because of their ability to provide services and data for high population density areas on a 24-hour basis.  Thankfully, we can sometimes use eccentric orbits to clear specific coordinates in GEO for new satellites.

Space Insurance:  Potentially, we could create a cleanup fund where everyone pays for our services before anything gets cleared for launch. Pre-launch deals could help reduce planning expenses and make a stable revenue source before putting a single thing in space.

Launch insurance is nothing new in the space industry.  However, costs increase as the risk factor from space debris increases.  Munichre is a German company that offers In-Orbit insurance, which covers space junk and liability.  – Munichre  There are several other providers.  Including Lloyd’s of London, Marsh, Beazley AXA XL, and Allianz.

We would also offer secure disposal contracts. These would guarantee safe and secure destruction and recycling of sensitive or secret projects. All data storage media and information gathering equipment will be erased, and the hardware destroyed entirely (ground into dust).  These contracts could involve the Russian and American Military for projects like secure radioactive material recovery and disposal.  There is money to be made from recycling and reclaiming things manufactured during the space race. If we decide never to go into space again, we would still have an outside shot of breaking even.  (See section on the forgotten arsenal)

Restored satellites could be retooled for new projects and sold for profit, provided we first acquired proper rights from the previous owners.  These contracts would probably include private companies, national and international government entities, and the militaries of said governments.

While this project is specifically designed for low Earth orbit, It should be noted that demand for GEO life extension missions will grow to 75 satellites by 2030, according to a recent Northern Sky Research (NSR) forecast.  GEO servicing represents a $3.2 billion cumulative market opportunity.  NSR analyst Hussain Bokhari expects more than 230 in-orbit satellites will be serviced in some way during the next ten years, with governments and militaries also driving demand in GEO and non-GEO. These missions include relocation, salvage, and repair services.’  – Spacenews.  

Recycling on Earth is usually done on a grand scale.  Some of the more advanced industrial plants back here on Earth can process more than 10,000 tons of plastic an hour.  This factory will be significantly smaller and highly adaptable.  The target recycling goal is 1 ton (0.8 metric tons, 860kg) of material a day (86400 seconds at 10g per second).

There have been recent breakthroughs in robotic space construction.  Robots like the Gitai series are more efficient for related space-related tasks than humans. Robots do not need sleep which allows the station to operate 24/7.  Using robots is also safer and cheaper, especially for EVAs.

We have already built micro-factory elements and closed-loop recycling machines for space.  As companies such as Redwire and Nanoracks achieve their objectives, this project will become cheaper and more manageable.

This project would greatly assist our ability to assemble important things in space.  We will start by building more salvage craft (RJB) to speed up salvage, restoration, and recycling operations.  This creates an economic loop  (see Retrieval JunkBot salvage craft)

The advance and expansion of fiber optics back here on planet Earth and the slow death of cable TV could also potentially render several currently active satellites obsolete. This station could give those satellites and materials a second life. Even GPS is usually done with WiFi these days.  Alternatively, we can help expand said fiber optics with Zblan, a higher-quality fiber optic cable that can only be made in zero gravity.

The salvage missions will likely require more launches for refueling missions. After running several simulations, it has become clear that this project will only work by building spacecraft with an ion thruster or several ion thrusters, using noble gas or iodine, a halogen(group 17) for fuel.

There were space construction and repair projects proposed in the early 70ʼs.  They built the space shuttle specifically for this purpose.  Unfortunately, things did not happen as planned.  Skylab was deorbited, Freedom station was delayed.  We did not get to maximize the full capability of the shuttle until the ISS was built.  We are looking at a new leap in technology.  We accomplished our objectives.  It’s time to take what we have learned and move forward.

There could be a profit in shipping products back to Earth.  There are expensive raw materials such as small quantities of weapons-grade Uranium and Plutonium, Precious metals like Platinum,  advanced materials such as Zblan, and other specialties made in space.  Techshots 3D printer was tested on the ISS and can print human organs.  They have high financial value.  The technology for light sample returns, such as a single human organ from low Earth orbit is old.  It was called a “keyhole” in the early days of space.  The process was used to ship film from spy satellites back to Earth in the early days of the space race.  We are already good at sending tiny packages back from space.   

Suppose we use reusable spacecraft such as Dragon, Orion, Starliner, the ESA’s new Susie, the X-37B, Dreamchaser, Starship, or whatever else comes next. In that case, the cost of shipping things back to Earth would be significantly reduced. However, the cost per launch still makes materials much more valuable in space.  In contrast, If the station is positioned in a similar orbit to the ISS, like SL-8 RB 1976-108B, we would be able to recycle Cygnus and other crafts that are not built for re-entry and for failing or obsolete modules.

This project does not require a citizen lottery and probably will not involve crowdfunding.   It could be funded as a stand-alone commercial venture involving a select group of Aerospace companies and capital investment firms.  However, getting grants and compensation from the United States government might not be impossible.

It would take an act of congress:  The annual NASA budget is 22.5 billion dollars.  This project’s scope is immense despite several attempts in this proposal to cut the cost down.  The current cost estimate is nearly thirty billion over twenty years, around 1.5 billion per year.  NASA doesn’t have those extra funds.  After 2025, NASA may no longer be responsible for upgrading and maintaining the ISS.  Things at NASA can be cut, but they are massive projects with the gears already in motion.   Some research and development could come from the Space Force’s annual budget of $15.2 billion.  They are currently working on a dedicated space junk removal program called Orbital Prime and looking for ideas and, in many ways, have been the strongest advocates for this project. Unfortunately, the recent war in Ukraine has likely put a hold on the project.  With all that in mind, the first chance for funding comes from bills centered around environmental action, such as the New infrastructure bill.

The Infrastructure bill made funds available for NASA to study climate change.  NASA received 1.11 billion dollars.  Perhaps this fund could be tapped for initial research and design.  –Space Policy Online    

The Green Premium is the increase in cost to produce things without ecological impact.  This project helps to stimulate the technology necessary to reduce that cost, making a zero-carbon world more feasible.  Currently, Jet fuel at the green premium is Twice as expensive.  For every dollar spent on the Apollo moon program, $8 was generated from innovation.  We think we can make the green premium a green surplus.

Another more likely option for funding could come from the commercial sector.  Good-natured billionaires like Elon Musk, Jeff Bezos, and Bill Gates exist.  However, it doesn’t have to be something so extreme or one-sided.  The world is changing fast. Companies have more incentive to get behind a project like this than ever.  Funding could come from corporations like Walmart, Koch Industries, or ExxonMobil.  Funding would likely come from several sources.

This project is a job creator.  In addition to the nearly 5000 people YSpace intends to hire directly for the space project, we estimate that it will create at least another 100,000 Medium income recycling, manufacturing, and energy jobs in the United States.  The scope of the project puts focus on the necessary skills needed in the future.  

Yspace is not the type of company to bet on a disaster.  It is better to prevent one than profit from one.  However, if there were a catastrophic incident involving space debris, funding for this project and other projects like it could become immediately available.

Cost Comparison: 

Before we go into how much it will cost. There are a few numbers that need to be crunched. How much will it cost NOT to do it?  A significant factor is the cost and danger of space junk and its effect on the cost of future launches.  The worst-case scenario would be the destruction of the ISS.  One nasty collision could make this project necessary. 

Relative Space Station Costs: 

• This Project. – $29,602,760,000 (Maximum)
• ISS – $150,000,000,000 (to date)
• Salyut – ?
• Mir – $4,200,000,000
• Skylab – $2,200,000,000
• Orbital Reef – TBD
• Axiom stand-alone Station Module – TBD
• Fabfuel fuel depot – ?
• Tiangong Chinese Space Station – $8,604,741,000

Cost to Orbit: SpaceX currently provides the lowest cost to low Earth orbit per kilo – $2500. The project would need to recycle 4,000,000 Kilograms of material or 4000 Metric tons to recover project costs. While the project would break even in low Earth orbit – fuel costs, the ability to restore, retool, and reuse will offset that number. There will also be several more tons of space junk in low Earth orbit on an exponential scale in the near future. The bad news is that space junk will become less valuable as the cost to low Earth orbit comes down. The good news is that there will be more space garbage to recycle. The space shuttle was designed to meet similar economic ideals. This objective for the shuttle failed when the cost to orbit dropped to a point where it was cheaper to send up commercial satellites using newer uncrewed rockets. 

This project is an attempt to “Beat” the rocket equation. The project has the unique ability to salvage parts and fuel.  We win when recycling space materials makes projects in space cheaper than launching them from the ground.  

Price at the pump:  No matter how good the system we send up is, no matter how many orbital mechanics tricks and shortcuts we use, there is absolutely no way to cheaply provide the delta-V necessary for the project without refuels from the ground.  We can use Ion thruster-powered Salvage spacecraft.  We can make some fuel.  These resupply launches are not currently factored into the proposal price estimate.

Brass Tacks: 

The Cost has been generously calculated with research and development that might be unnecessary or redundant.  This number represents the absolute maximum the station will cost.  Most of the cost was calculated by determining how many people would need to be hired and for how long.

Staff Numbers are determined mainly by the current engineering state of systems and subsystems (see system engineering project class variable.)

The number of employees: 5504 over 20 years.
Average salary – $150,000 (yr).
Benefits package – $6000 (yr).
Travel Expenses – $6000 (yr).
Total Average employee cost per year- $162,000.
Total Salary cost per year – $891,740,000.
Total Salary costs for five years – $4,458,240,000.
Total salary costs for twenty years – $17,832,960,000.

Project costs:

Third-party contracts: $1,069,800,000 (est).
Materials for spacecraft and station production: $200,000,000.
Ground control facility: $1,000,000,000.
Manufacturing facility: $2,000,000,000.
Offices: $500,000,000.
Operating Costs: $5,000,000,000 (over 20 years).
Estimated  Launch costs: $2,000,000,000 with five heavy launches provides room for error.
Those unforeseen problems: X multiplier.

TOTAL: $29,602,760,000

Estimated Profit:

Total profit from recycling: $14,000,000,000.
Total tonnage recycled: 6,000 metric tons. 
Average materials value per ton: $200,000.
Tonnage recycled per day: 0.821.
Expected ROI: 2,115 days or 6.3 years.
Expected lifespan of station: 20+ years.
Returns from servicing and restoration: ?
Returns from in-orbit assembly: ?
Returns from manufacturing: ? 
Returns from Refueling: ? 
Returns from Secure Disposal: ?  

There are more financial details at the bottom of the document.

– – – – – – – – – – – – – – – – – – –

Launches and Payloads:

It is expensive to put a payload into space. The price is coming down, but not fast enough. The rocket equation dictates that 80%+ of the mass of a rocket is fuel. We launch the same things into Low Earth orbit over and over.  It makes sense to manufacture stuff in space rather than constantly expend Delta-V, time, money, and resources to launch everything from Earth.  Every kilogram we salvage is one less kg we would have to launch from the Earth.  One more kg of material is available for space construction and repair projects.  It helps that whatever we build or salvage in space has already paid the velocity investment to be in orbit.

Reusable rockets are a great start and provide lower-cost access to space.  It’s wonderful to see reusable rockets carry larger and larger payloads.  This station would be a fantastic continuation.  Additive manufacturing with recycling allows us to print parts and electronics in low Earth orbit without a rocket launch.  The servicing bay allows us to restore and augment existing spacecraft and station components.  It might also allow us to assemble new things.

There is an expression used in the space industry.  CATS: Cheap Access To Space.  The lower the cost to orbit, the cheaper the initial project will cost.   It is amazing to see some of this vision realized.  SpaceX is working on Starship but also has developed a Dragon XL capsule for use on a falcon heavy.  Rocket Lab and Blue Origin are building bigger reusable rockets.  There are a host of new air-launched rockets like the pegasus, Virgin Orbit, or Aevum’s Three-stage autonomous drone launch system.  There are also other alternative launch systems, such as SpinLaunch.  They are building a frictionless circular magnetic track where the launch vehicle moves in a loop, constantly accelerating until it reaches the required speed for an orbital trajectory.

Swords to Plowshares: Watching the recent NRO Launch on a Minotaur ICBM (July 15th, 2020) gave me a little stir.  In an attempt to align our vision in space with the current launch industry, industrial restocking and fuel resupply could potentially be done with Recommissioned ICBMs.  Realistically, we would likely have to go with one of the aforementioned traditional launch providers.  It is a nice thought anyway.  Recycling weapons into instruments of peace and prosperity.

One amazing element of the modern space industry is the sheer number of launch providers.  There must be 100 launch providers, public and private, worldwide.  Some providers can only put <10g per launch into orbit.  A few providers can put over 100 tons into orbit.  The rocket industry is literally exploding.

The ISS required several construction launches using the space shuttle, which for better or worse, is no longer an option.  It also needed 100ʼs of uncrewed launches, including 30 refueling missions using the Soyuz Progress spacecraft.  Hopefully, the uncrewed space station will not require more than five launches with additional resupply launches.  The Freedom station turned ISS (International Space Station) took 25 years to design and cost over 150 Billion dollars.

The rebirth of heavy lift rockets:  Today is November 16th, 2022.  An SLS rocket is on the pad, ready to launch the Artemis 1 mission to the moon in 5 minutes.  After years of delays and setbacks, no one was sure this day would come.  Surprise, it is here.  The dawn of a new age of heavy-lift rockets.  The SLS is not reusable.  Every Space Launch System (moon rocket) contracted to be built is allocated for a project-specific task.  They are not cheap and come with a hefty price tag of  2.5 billion dollars per launch, excluding development costs. There will not be any extra rockets.  However, they exist.  There is a big difference between expensive and impossible.  There is another heavy lift project.  Starship by SpaceX is also in the works.  Starship promises a much lower cost to orbit and a greater chance of availability.  By the time this project comes into focus, there will likely be several heavy-lift options to choose from.  When I started writing, there were no heavy rockets. We are less reliant on heavy-lift rockets because we will be operating exclusively in low-Earth orbit.  It is the easiest and cheapest place in space to get to.

If we go with the initial Hermit Crab Drylab design, there is no need for heavy-lift rockets at all.  If we end up with the ability to use a rocket like SLS or Starship.  We can build and launch the robotics bay from the ground.  The first launch (the robotics bay) would be a heavy rocket.  The rest could probably be launched on a falcon-9 or equivalent rockets.  If we use a heavy-lift rocket, we can combine launches 1,3,4, and 5. (see mission one)

Launch 1: Cargo SpaceCraft, RSV, and Robotic Workers: The first mission would be to set up shop.  We must launch everything necessary to build out the robotics bay and make it minimally functional.

Launch 2: The second launch will happen very quickly after launch 1.  Launch 2 is the largest space tug we have at the time.   It will be many weeks before it makes its first salvage run. However, we need it to provide power and communications, hold the station position relative to the sun’s direction, and prevent any spin. We hope to launch a 40-ton space tug with around 40 ion thrusters.  (see space tug)

Launch 3: The third launch is a follow-up to the first.  More maintenance bay robots and robotic arms.  Parts for the workstations.  Dedicated solar panels.  Heat piping, initial components for the material transfer system, batteries computers communication

Launch 4: An expandable truss for service bay structural support with much larger heat radiators and solar panels, reaction wheels, and the first external robotic arm.

Launch 5: structural supports for expanded truss and docking ports.  A second robotic arm and tools.

Launch 6: Factory casings and pneumatic tube system.

Launch 7: Sorting and shredding equipment.

Launch 8: Production modules for plastic and metal, 3D printing, and additive manufacturing.

Launch 9: Furnace and refinery modules.

Launch 10+: Fuel for Ion engines for salvage craft refueling. service parts. return payloads.

Project Classes: 

For the rest of this document you will come across the term Project Class.  The project classes determine how many people would need to be hired, which helps quantify the cost of the project.  It is not perfect, but it’s something.  There are 3 project classes: NEN (No Engineering Necessary) – 8 people required, EEC (Some Engineering Necessary) – 32 people required, and ES (Engineering from Scratch) – 64 people required.  There is much more info at the bottom of the document.

– – – – – – – – – – – – – – – – – – – 

Fishing For Space Debris:

The Greek god of water, Poseidon, uses a harpoon (trident) and a net in reference to space debris capture tactics. When told about the project, an old friend, Jay Queenin mentioned A whaling fleet.  A whaling fleet operates with several small boats which kill whales and drag them to a much larger whale processing ship.  The MEV uses a hook pushed into the engine bell of a Satellite for stability and then uses its own engines to reposition the satellite.  Nets work for rapidly spinning objects.  Harpoons are only effective if there is less worry about the integrity of the satellite after capture.

The Space Janitors: The Cleanup Crew. (Mitigation) 

RSV: (Remote Servicing Vehicle) DARPAʼs term for the construction and repair, robotic spacecraft. The RSVs are being developed for DARPA’s RSGS (Robotic Servicing of Geosynchronous Satellites) program. There are well-funded plans for future craft outside of this proposal.  Restore-L is now being built by NASA and is termed OSAM (On-orbit Servicing and Manufacturing) instead.  A few RSV projects are as follows.

MEV-1 and 2 (Mission Extension Vehicle): Built by Northrop Grumman.  It was launched a few years ago, early in October 2019 and again in August 2020. While mentioned in the first draft of this proposal, its timeline has been accelerated.  It launched a few months before its projected deadline, nearly a year after the first version of this document.  It is designed to change the orbits of satellites in Geosynchronous orbit and extend their life by five years or more. The MEV is built to last at least 15 years. One MEV can service several satellites throughout its lifetime.  So far, the mission has gone flawlessly.  The project is a success, even though its role as an RSV is limited.  However, when combined with a central service station, it becomes a significantly more useful spacecraft.  It makes for an excellent, albeit small, space tug.  This low-cost and highly effective craft could be the basis for the project’s transportation workhorse.  It is built on the GeoStar-3 satellite platform.

 Grumman is working with DARPA on a new version called the MRV.  It will feature a new robotic arm designed for Satellite servicing.  It will also have a new feature called MEPS (Mission Extension Pods).  Instead of docking to the satellite, the MRV gets close and launches a smaller Cubesat-sized Mission extension vehicle which functions as a jetpack.  It allows the MRV to service at least three more satellites in a single launch.  I tried something similar to the MEPS in Kerbal Space Program before the Grumman started their research.   It worked, but not in the way it was intended to. Check out Space Clip in the section of spacecraft that do not exist yet.   MEPS, Space.com

Project Class: NEN

Weight: 2326kg

Orbit: GEO

Link: https://www.northropgrumman.com/

The MEV Kerbal:

KMass: 2.6t (3t augmented) We made 2 MEVs in KSP because the design is perfect for the recycle station workhorse.  Its ability to use multi-directional Ion thrusters to establish proper orbits is impressive.  The augmented Kerbal version includes a docking port on the back and RCS thrusters.  Both of these things are necessary for work from a central station.  It has a massive energy requirement to power the Ion Thrusters. Therefore, it requires extra solar panels and batteries.  There is one drawback.  The MEV doesn’t have enough thrust with its ion thrusters to move most rocket boosters significantly.  However, for a small-sized space tug, it does a great job.  In reality, it could probably only move mostly empty 2nd stage boosters, but not first-stage boosters, shuttle fuel tanks, and the like.

Restore-L  (Maxar): OSAM-1 is planned to be launched in 2022… 2025.  It is based on the SL-1300 chassis, which has been used many times.  The project was commissioned by NASA.  It can refuel other satellites and use advanced tools to do repairs.  It can be mounted with robotic arms and cutting tools, specifically a circular saw (Rachit SSCO), a drill/screwdriver with wrench attachments, and other toolboxy-type equipment.  Restore-L has undergone several iterations and is now the lead project for OSAM.  Its ability to refuel other satellites likely comes with the condition that it runs on hypergolic fuel.  Unfortunately, the limited efficiency significantly reduces mission lifespan and functionality compared to the MEV-1.  Restore-L is now OSAM-1.  Archanaut is OSAM-2 (That makes this project something like OSAM-6 or 7)

Project class: NEN 

Weight: 6700kg

Link: https://sspd.gsfc.nasa.gov/restore-L.html

Restore-L Kerbal

Kmass: 2.994t OSAM-1 in kerbal isn’t a viable spacecraft.  It doesn’t have enough reaction wheels to control the robot arms without throwing the ship into a spin, the center of mass is wrong, and frankly, the shape is too weird for the game.  But this is the best mockup I could manage in the game.  It has a very odd construction.

LEO Knight by Tethers Unlimited satellite servicer is a small servicer that runs on liquid water.  It is lightweight even when fully fueled.  The LEO Knight has an easy-to-refuel propulsion source.  It is designed for smaller satellites. It can also deliver ESPA payloads which is a multiple satellite launch system.  

Project class: NEN 

Weight: 183kg
Orbit: LEO
Link: http://www.tethers.com/

LEO Knight Kerbal:

The LEO Knight Kerbal is similar to the Restore-L.  It is designed for aesthetics only and has no function in the game.

SPS Genesis spacecraft is an SPS. SPS stands for single-person spacecraft.  Its main function is EVAs as a safer, more functional alternative to the current spacesuit.  Its ability to be teleoperated makes it of particular interest to this project.  It might have the potential to do servicing and construction for the station.  It might be easily adapted to work in the robotics bay.  SPS could potentially end up filling a multi-function role.  However, it has not been tested in space yet, although it did well in neutral buoyancy tests.   It is similar in design to DARPA’s project phoenix but built for shorter-duration missions and a single person.  They do a study to show what is different compared to just a spacesuit.  

Link: https://genesisesi.com

Another more detailed link:  Genesis PDF

Project class: NEN

EMU Space suit is a spacecraft for one person.  (photo of kerbal floating in space)

Ares second stage: (Vulkan Centaur United Launch Alliance)  As of January 2022, they haven’t finished building this rocket yet.  Part of the hold-up is because they contracted Blue Origin to use the BE4 rocket engine, which has just finished development as of October 2022.  It is several years late.  There is one cool innovation.  The second stage of the new Vulkan Centaur can also function as a space tugboat.  Unfortunately, we haven’t heard much about its alternative function in a few years.  It might have been canceled.

Project Class: NEN

Weight: 2016kg (dry) 22936kg (wet)

Link https://www.ulalaunch.com/rockets/vulcan-centaur

The Mysterious X-37b: USAF reusable orbital space plane has a tiny robotic arm and a small payload bay.  It functions as a multirole surveillance, servicing, and sabotage spacecraft.  It can collect a small payload, at least the size of a cubesat with its robotic arm, then put it into its bay and return it to Earth.

Project class: NEN 

Link: https://www.af.mil/

Weight: Classified

X-37b Kerbal:

Kmass: 3.4tThe X-37 Is a cheap, lightweight, and effective spaceplane.  Unlike the space shuttle, it can fit in a medium-sized or small fairing.  It can be launched with a proper center of mass. Its ability to service anything large is limited.  However, it seems likely that it could potentially service small satellites.  It has a  small “shuttle bay,”  allowing it to safely move highly sensitive payloads back to Earth.  If I had to get some plutonium back to Earth from a dying spy satellite, this is what I would use.  Otherwise, it is too much work.  Why not just build something that stays in space?  That said, it is an absolute joy to fly.

LINUSS: Linuss is a pair of Cubesats internally developed by Lockheed Martin.  They are about the size of a toaster.  They are designed to service other satellites in geostationary orbit.  They are based on the LM-50 design for Lockheed small satellites.  They haven’t divulged much about its capabilities.

Project class: NEN 

The Apis Mining Minibee: from TransAstra is in its beginning stages but shows some promise.  It creates an enclosed space to do optical mining using solar reflectors.  One of the advantages of this design is the enclosing bag which prevents dangerous debris from escaping while using a thermal process to refine the ore.

Project class: NEN

Link: https://www.transastracorp.com

Weight: 250kg

The Apis Mining Minibee Kerbal:

The Apis Mining Minibee mockup.  It is an interesting concept, for sure.  Aim the mirrors toward the heat-generating source and melt off the thing being mined.  It works better with Ice.  It can work with other things, but the concept is mainly based on how to get oxidizer and Hydrogen from an Ice asteroid.  There is an upscaled model that could potentially use the solar furnace for more space junky concerns.  It would function as more of a station component.  It has promise for sure.

Remove Debris was launched in 2018. It is a CubeSat built to conduct four experiments.  The first involved launching a balloon and a net that wrapped around the target and de-orbited the debris. Debrissat2 was their second experiment and involved an advanced sensor package for tracking the target. Afterward, the DebrissatSS2 used a harpoon to catch the object. The fourth experiment is a spacecraft with a drag sail, which is meant to bring satellites down into Earth’s atmosphere, where they will burn up. Genius but wasteful.  Perhaps it can be reappropriated as a salvage tug.

Project class: NEN

Weight: <100kg

Orbit: LEO
Link: https://www.sstl.co.uk/ 

Clear Space-1: Clear Space 1 uses four basic robotic arms to capture debris.  The robotic arms are electrostatic.  The Swiss space agency claims that it is like an octopus arm.  Its first mission is to remove a Vespa second-stage booster from orbit.  It is a disposable craft that can be launched in a palette format, with several Clearspace-1 vessels launched simultaneously.  It uses a single small ion thruster for propulsion.  They plan to launch before 2025.

Project class: NEN

Elsa-D Space Debris: by Astroscale.  The Elsa-D is a small spacecraft that uses magnets to attach to space debris and drag it down into the atmosphere.  It was successfully tested on August 25, 2021.   Elsa-D gets points for being successful.  One problem is that it is a use-once solution in its current form.  All of the space debris spacecraft seem to suffer from this problem. It will cost several million dollars per piece of debris de-orbited.  That said, it does provide a decent platform for moving space debris around low Earth orbit.

Link: www.astroscale.com
Project class: NEN

Tetra-5 satellite Orion Space: On-orbit Satellite servicing project.

SJ-21: A Chinese satellite space tug that uses the swooping crane technique.  It is a can with a net. and an ion thruster.   Honestly, it doesn’t get more simple. SJ-21 is made to operate in geostationary orbit.

Susie ESA’s manned spacecraft has a service bay

Lexi Spacecraft – Astroscale

The Space Shuttle:  The ultimate human-crewed service vehicle.  Almost every satellite servicing mission to date was done with the space shuttle.  It had a massive servicing bay and was designed specifically with servicing and space construction in mind.  The Space Shuttle successfully repaired the Solar Max satellite and the Hubble space telescope several times.  The shuttle’s robotic arm and EVA equipment were instrumental in building the ISS.  Expensive? Yes. Safe?  No.  However, there will likely never be a spaceship as versatile again in our lifetimes.  We would use it for this project in a heartbeat if it still existed.

There were several alternate shuttle configuration proposals.  There is one plan to make a space shuttle fuel tank into a telescope from DARPA.  See Figure 11.  Unfortunately, there are no shuttle fuel tanks in orbit.  

Link: https://www.aiaa.org/docs/default-source/uploadedfiles/about-aiaa/history-and-heritage/shuttlevariationsfinalaiaa.pdf

Space Shuttle Kerbal:

One hundred years from now, people will doubt that this thing ever flew at all.  Nothing about Launching a space shuttle is easy.  The Shuttle is strapped to the side of a fuel tank that doesn’t have a rocket engine at the bottom. The other boosters are SRB’s.  The configuration creates an odd Center of thrust.  The second but just as serious issue is the center of mass, which is off-center.  The shuttle’s liquid fuel engines must provide a counter thrust to the solid rocket motors.  They must be set to a severe gimbal on launch (about 30 degrees). It has to do a ridiculous roll maneuver shortly after takeoff when the atmosphere is still thick.  It is way too heavy.  It has to survive re-entry, and then It has to land like a glider.  It took me several days to build one, put it in orbit, bring it back, and land it.

The following spaceships DO NOT EXIST yet. They are specifically designed for this project.

Podship First, let us talk about the pod.  The pod is a multi-use storage container and internal materials transfer vessel for use inside the station.  The pod is cylindrical and about the size of a pneumatic tube mail container and is designed to work in a pneumatic tube.  You will read about them later. Its cylindrical nature will help the pod fit in a standardized rocket-shaped cargo bay.  DARPA has/had a proposal with requirements for a small spacecraft capable of moving light cargo in space.  It would make sense to design it with the standardization built into our pod system.  The pod has its own section with more detail later in the proposal.

The podship can take many different forms.  The simpler, the better.  It would be amazing if the station could build the podship on-site.  Its main design function is to hold the standardized pod.  It would probably take the form of a cylindrical bay with two doors but pint-sized, or likely closer to a gallon-sized.  It will likely be simple with a single ion thruster, small solar panels, and a noble gas fuel tank.  It would have a universal docking adapter.  The podship would also have all the standard ports built into the docking adapter, exactly like the pod.  The spacecraft would have fuel and gas transfer nozzles and a datalink, clamps, handholds, and other mechanisms for grabbing or manipulating the ship with robotic or even human hands.  It could have a tiny toolkit area for easy access and emergencies with a multitool, glue, tape, rope, or whatever small things a mission might require that won’t fit in the pod.

In the optional section of the proposal, there is an idea for a railgun-type magnetically driven launcher.  If a kinetic launching device were included, the podship would be designed to work with it.  After servicing, the podship also helps with the initial burn for placing small satellites back into specific orbits.  If the Podship were to be used as a return capsule.  Where it functions as a sort of keyhole-type return vessel.  It might be possible to easily use an engine bell by cutting it and squeezing it with one side curved in on itself at a slight angle so that it becomes a cone with a point at the top.

“Spacegram – Pod delivery service”  The standardized containers would fit into a small specialized spaceship in order to ship things from the station to other locations in space or perhaps even back to Earth.  . .  The pods might be able to help with refueling small satellite or with repair when used in conjunction with other spacecraft.  

Example:  We know something is wrong with the satellite, but we don’t know what.  We send a servicing craft to fix it and discover a broken solar panel.  We could ship a rolled-up solar panel in a pod to the repair craft and satellite in question.  The ability to send on-demand resources could save the heavier servicing vessel valuable fuel and time.

Size >1m
Weight >200kg (without payload)

Project Class: ES

Tugboat, Garbage truck:  There have been several Tugboat-type craft proposed, but unfortunately, none of the mockups were able to do the job.   This ship is designed primarily to move rocket boosters and other large and unwieldy debris that doesn’t have specific mount points or docking ports.  Rocket boosters present a series of problems that require unique solutions.  The first problem is the mass.  The heavier the debris is, the more propellant is required to move it.  Furthermore, you need more ISP to move rocket boosters in a human timescale.  The larger the debris is, the harder it is to attach to the booster with an accurate center of mass and thrust vector.  Get it wrong, and all you will do is send the booster spinning in circles.  This craft would also need to be heavy on reaction wheels. This design features large center wheels with smaller reaction wheels mounted on the outer ends of the trusses.  These outer reaction wheels stabilize the craft and its payload and extend the center of mass in a broader radius.  Thus, simulating a much bigger and more stable ship.  Using several ion thrusters allows for enough delta-V to Safely move several Boosters with a single space tug enabling the ship to conduct several Low Earth Orbit missions without refueling.  The Space tug design seems easy at first.   But you have to consider some of the more expensive elements of the ship.  The first being how to make extremely large fuel tanks for noble gases.

One of the proposed spacecraft is  Optimus-1 a small space tug built by the Australian-based Space Machines Company (SMC).  It is designed to work as an OTV (Orbital Transfer Vehicle).   It is small, weighing only 270 kg.  The spacecraft is meant to carry payloads from rockets into their proper orbits in space.  Optimus is also capable of in-orbit inspections and de-orbiting services and will be launched in 2023.  – Spacenews.com

Project Class ECC

Space Tug Kerbal:

Space Tug Kmass: 36t I moved a half-full 3.5m x 10m booster weighing more than 80 tons using a 36 Ton Vessel with 40 Ion Thrusters.  These Thrusters sit on servos that turn 360 x 180 degrees to allow a super gimbal effect.  The servos sit on 4 2m trusses which fold out with industrial alligator clips.  The trusses are mounted on the starboard side.  The thrusters are mounted ten per truss, five on each side.  It is a broad base to work with, which is essential.  That broad base allows the ship to mount 40 thrusters.  They operate with a differential where the engines run at different outputs and directions.  The tugcraft can offset its center of mass and carry the booster along the proper vector, even if the mount position is less than optimal.   The super gimbal allows the spacecraft to go forward and backward without turning around.  The extra movement is necessary because it becomes complicated to maneuver after the craft is attached to a rocket booster. Ion Engines require an immense amount of energy to use.   The massive and plentiful solar panels have been positioned to optimize energy input while taking advantage of the broad base for maximum efficiency.  The entire center section of the spacecraft and a significant portion of the weight is batteries. I tried several incarnations of a space tug before this.  None of the prototypes were able to effectively move a discarded rocket booster without using so much fuel that the space tug could only be used once without refueling,   even with Nuclear engines.  That fuel comes from the planet. No fuel means you have to do another launch.  That launch also requires a massive amount of fuel, and we left fighting an uphill battle against the rocket equation. This ship can tow 80+ tons into orbit anywhere in the solar system.   This ship can tow large asteroids.  I am not a proponent of brute force.  It was a desperate attempt after several failures.  However, it works well.  You can do several salvage operations on one fuel tank, and it doesn’t cost a fortune at the pump either.    It was the most expensive spacecraft I have ever built in Kerbal and cost more than multiple station component launches combined.   The high price comes from the Ion Thrusters and Thruster fuel cost.  In reality, Xenon tanks are highly pressurized and difficult to make. This ship is the crux of the recycling program.  Its effectiveness proves that the project can be done.

Retrieval JunkBot (RJB*):  This spacecraft is assembled from spare parts for the purpose of collecting more space debris.  What does the junkbot look like?  It looks similar to many satellites of old.  It is, in fact, said satellites of old.  They have been modified for the specific task of “go fetch.”  In many ways, this is a core project.  It allows some sustainability to the process. This ship would have almost none of the OSAM project line’s capabilities but would function more like Northrop’s MEV project.  It would have elements of the remove-trash concept but more oriented toward re-positioning instead of de-orbiting.  A first step would be removing the solar panels, antenna, and anything else that protrudes from the craft. The next would be disabling all nonessential electronics.  Lastly, we would add a docking hardpoint.

We hope to build something similar to the MEV from SpaceLogistics (Northrop Grumman).  While the MEV is built to extend craft life by latching on and acting as the guidance and propulsion systems, this craft would latch on and pull it back to the Station.   It would not be impossible to retool dead or obsolete satellites, such as the wide chassis Telstar series, into something like this. 

Another incarnation of the Retrieval Junkbot could be a “jetpack” backpack designed for the humanoid robots in the repair bay.  This propulsion system could be mounted on a robotic worker from the service bay.

JunkbotCraft Propulsion:  It would likely run on whatever the craft had initially or whatever we can salvage and apply easily.  We can use hypergolic fuels provided we can salvage more Hypergolic fuels per mission than spent.  Otherwise, we have to ship hypergolics from the ground.  Salvaging space junk could require a massive amount of fuel.  Optimally we would use ion drives using Xenon or Krypton, such as the HET Hall-Effect Thruster.  This proven technology is used on the Parker solar probe.  Ion thrusters are also used in the Northrop Grumman MEV.  However, ion thrusters don’t have much KN of thrust.  We could try something weird like a photonic drive along with a solar sail or Accion’s TILE engine for micro thrusts or go with more traditional cold gas, warm gas, hot gas, liquid monopropellant, liquid bi-propellant, solid like aluminum perchlorate, or solid like Teflon slugs which are in some Russian ion engines.   There is also a new Ion thruster which uses Iodine for fuel.   Iodine is a group 17 halogen fuel which isn’t a noble gas, and has distinct advantages.

The larger the debris, the more KN and Delta V is needed.  There is nothing wrong with slow salvage operations, but waiting decades for a salvage return won’t work.  More propellant requires more launches and more money.  Another rather extreme option will surely work but is a little risky.  It might be possible to equip junk bots with a Nerva nuclear Ion drive run on recycled Russian Uranium.  Nuclear electric propulsion would create enough delta-V to make the project worthwhile.  Different Junkbots can run on other propulsion systems.  This project provides the luxury of room to experiment with different builds.

RCS thrusters and monopropellants are handy for rendezvous and docking procedures.  Though, the MEV provides an innovative solution using a multi-directional ion thruster instead of RCS thrusters.

Alternative rendezvous technologies:  
– Adhesion Metallic Microspines (little hooks). 
– Anchoring.
-Boston Dynamics (robot) gecko grippers 
-Electrostatic
-Electromagnetic 
-Velcro and rope/cable with knots.

There was a Stephen Spielberg movie called “Batteries Not Included” (1987). The stars of the film are a family of intelligent alien robots, all smaller than bread boxes.  They self-replicate using broken disposable electronics and love fixing things.  There is a concept in science fiction called the von Neumann probe.  It is a spacecraft which self replicates.  The craft functions as a factory of sorts and harvests materials to reproduce itself.  The Junkbot along with the station is a pre-alpha version.

Project Class: ES

Power consumption: 80 watts+  (More with ion engine)
Size/Weight: Variable.
Propellant: Variable.
Total Cost: FREE(ish) Time, parts, and labor only.  Maybe not even parts.

Catfish Small Debris Collector:  There are no fish-type proposals here, but it does make a nice image.  More than half of space debris by numbers is too small to salvage, but in some cases poses a bigger risk than the big stuff.  Microscopic dust can create monumental problems.  Think of everything under 10 cm as a bullet that can impact with the force of several sticks of dynamite.  Furthermore, tiny things are much harder to track.  After working on this project for several years.  These are the best ideas I have.  The solutions are not great, but it is a difficult task.   We might be able to use a scoop arm for objects smaller than 12 cm but larger than 10mm, but smaller than 10mm, and we have to get very creative. 

“Imagine a spinning fluffy flower or ring, several hundred meters in diameter, ion drives in the middle, capturing a huge swath of dirty space every orbit.  Eventually, it gets so full of junk you make new fluffy petals and consume the old ones like a spider eating its web.” – Juggling lessons. 

His idea, while presented as a joke, has some serious merit.  A friend Chris Garfallo built a powder-coating paint station out of a large filing cabinet and a large discarded electric stove.  The powder doesn’t stick to the metal when you spray it.  Instead, you have to give the metal an electrostatic charge to get the powder to stick.  As soon as you stop the energy flow, the powder falls off.  (Unless you cook said piece first).  The fluffy flower petals would likely work similarly.

Option two is a laser (laser broom).  Some people donʼt like lasers in space, but it isn’t the worst idea for vaporizing flecks of paint and other tiny pieces of space junk. There are a few concepts in development.

Link:https://academictimes.com/orbital-lasers-could-melt-defunct-satellites-without-polluting-space/

Option three: Stink Sinker:  It might be possible to use gas clouds to de-orbit large spread out swarms of small objects by creating atmospheric density and slowing the small debris down enough that it falls back to Earth.  This could be a one-off maneuver where a ship pulls in front of the debris and fires its thrusters, creating a cloud of gas for the debris to travel through.  You would have to get very close to accomplish this.  It might not be a very safe maneuver.  The gas would dissipate extremely fast.  However, the advantage is that the gas particles would be traveling in the opposite direction from the debris and would hopefully have a better slowing effect.    

A gas cloud de-orbiting solution could also come in the form of a specialized ship. It would use a specific gas for the purpose.  The particularly stinky stuff that lingers around for a while  (and has a high density to cause more friction).  We are looking for a gas with strange qualities like the ability to not quickly disperse in a vacuum.  Again the craft would get out in front of the debris and release a sufficient amount of gas to de-orbit the debris swarm.  However, it would rely less on using dedicated Delta-V for the action and would instead use specialized gasses and dispensers.   

Option four: EctoShip.  The ectoship deposits a stringy layer of slimy film, like ectoplasm or Mucus, in a wide field with the hope of deorbiting small bits of space debris.  It might take the form of a light aerogel.

Option five: Parachute Ship. Deorbiting small debris swarms with parachutes.  With Kerbal Space Program, A kerbal can toss away its parachutes in space. One would do this to get an extra slot for Kerbalnauts.  After our fearless engineers ejected the 10th parachute into orbit to make room for parts during EVAs, the thought dawned on me that this might be a convenient way to de-orbit Microscopic debris,fields of smaller debris, or basically anything for a very low cost.   What is it?  It is just a parachute.  It could be a crusty old blanket.   The parachute is deployed slightly ahead of the debris field.  Toro toro!  The debris collides with the parachute at a reasonable speed.  The parachute folds in on the debris, capturing it and creating more drag, speeding up the natural deorbiting process.   Indeed, parachutes don’t actually deploy in space. They would have to be modified.  The materials can be changed for desired effects, such as incinerating some debris with the help of sunlight or preventing communications from operating, preventing satellites from using their solar panels, or visual sensors. 

Option six: Gravity Well.  It is a bit on the science fiction spectrum of things.  My thought is to move all the space dust, the dangerous stuff, into a specific orbit or central point where it can be collected and harvested safely using a micro black hole.

The most respected theory about how the moon was created goes like this.  Early on, during the Earth’s formative years, a planet crashed into the Earth.  A big ball of iron was ejected from the Earth’s core which had a magnetic attraction to the nearby debris, and slowly, over billions of years, the moon was formed from the ejected matter from the Earth.   

In the solar system, Jupiter has the largest gravity well.  Its gravitational force on some objects in Earth’s orbit is greater than the moon.   It is likely why no small asteroids are in orbit around the moon or the Earth.  Jupiter’s gravity sucks in most interstellar objects and debris from the solar system’s creation.  Without Jupiter, there would be an extinction event collision with Earth much more frequently.  

Jupiter is also responsible for removing the smaller debris from orbit around the Earth.  Its gravitational pull is so big that it moved all the small stuff into helio-centric orbit long before the dawn of humanity.  There are no Asteroids in orbit around the Earth or the moon.   

Smaller objects have a lower escape velocity or are more subject to gravitational pull than larger objects.  Jupiter managed to pull everything from that collision and subsequent collisions like the one that killed the dinosaurs 66 million years ago, except the moon, into helio-centric orbit. 

Currently, at the Hadron collider, they have been experimenting with gravity wells by shooting two protons together at absolutely ridiculous speeds.  They are trying to create a black hole, a gravitational anomaly, and have succeeded, albeit for a very short time.   We could potentially re-create these experiments in space to move the micro-debris into specific orbits without affecting the larger, more useful debris like rocket boosters.

“Gravity wells are for suckers” -Fraiser Cain, Universe Today

Project class ES 

Bishop DRI (docking rendezvous Inclination):  A depot in space designed to change the inclinations of salvage and salvage craft without expending fuel.  The idea is based on the Aerospace company Tethers Unlimited’s spinning tethers designs.  These designs are innovative and unique in that they allow for a change in inclination for free but don’t allow you to change your apoapsis or periapsis (altitude) at all.  There are drawbacks.  The tether has to be several km long.  It is slow.  There is concern about tangles or mishaps involving the unpredictability of a loose tether, but the fuel savings would be a game changer.  All credit to Rob Hoyt, the CEO of tethers unlimited, and his tethers research.

Scoutcraft:  A scout spacecraft that enters orbit or does a flyby around various space debris for salvage and recycling at a later time.  This small spacecraft would feature exceptional sensors and long burn-duration plasma thrusters.

Size >1m

Weight >200kg
Project Class: ES

Space Clip: This is an expendable debris de-orbiter.  It features two robotic grabbers on opposite sides.  RCS, monopropellant, command, control, and communications, two reaction wheels, battery, and solar panels.  This tiny ship is used to attach one piece of space junk to another piece of space junk.  It can also move small pieces of debris short distances.  The main advantage of this craft is its low weight and ease of construction.  Its lack of a main thruster means limited use, but in some cases, it can also deorbit space debris by doing a “suicide dive.”  Most de-orbiting spacecraft fit this profile, with one or two changes.  The Space clip idea was independently thought up at around the same time period as Grummans MEPS.

Trash clipperKMASS: 0.3t This ship was initially designed as a railroad hitch-type craft.  I mean that it was meant to link one piece of debris to another for multi-salvage missions.  It didn’t work as intended.  There was no way to get the center of mass right in Kerbal for the return trip to the station.  The ship uses the “tweakscale kerbal mod” for non-standard extra small parts like the grabbers and the RCS tanks. However, it did make for a great de-orbiter.  Also, its minimum weight allows it to be sent up in palettes.  (16 or 32 per launch easily)

Fuel Tanker: We currently use Soyuz Progress M-44 Cygnus or the cargo dragon capsule for refueling the ISS.  These are all very well-made spacecraft.  There is no doubt that any one of them could do the job.  However, it might not hurt to have something more modern. Perhaps something with several tanks for various liquids and gas for storage of recycled fuel and refueling satellites. SpaceX is also working on a much larger tanker for Starship.  It is essentially a Starship with no crew, just fuel.  Ultimately, it looks like Starship will be the solution.  The one caveat is that we need Fuel for Ion thrusters more than conventional rocket thrusters.  It includes the noble gases Argon, Xenon, and Krypton.  Those fuels require a great deal of pressure.

There is another project called Orbit Fab.  It aims to be a gas station in space.  It has Lockheed Martin and Northrop Grumman as investors.  It is being built for Starship.  Their flagship product is called Tenzing or Tanker-001.  It carries High-Test Peroxide (HTP) rocket fuel.  It was successfully launched in June 2021 on a Falcon 9 rocket.  It was built in 9 months from concept to launch.
Project Class: NEN

Link: http://en.roscosmos.ru

Link: https://www.northropgrumman.com

Link: http://spacex.com

Link: https://www.orbitfab.com

Nano SpaceBots:  How small can we make these things?  Nano is 10 to the -9 power Micro is 10 to the -6 power.  We can probably make them pretty small.  They can operate as a swarm.  It might be easy to make them self-replicate or build them in large quantities.  They are featured in Neal Stephenson’s book Seveneves and are used for automated mechanical repairs and asteroid mining.  It is future tech, and likely won’t be possible for a while.  Perhaps a swarm of nanobots could help collect or de-orbit microscopic debris.

Project Class: ES 

Emergency and Mishap Mitigation bot: This robotic spacecraft is explicitly built for emergencies. It can be equipped with standard maintenance tools and specialized tools such as an Argon Sprayer to super cool elements speedily or a foam sprayer that can rapidly solidify to seal leaks quickly.

Project Class ES

Construction Bot (BurndyBot): This is similar to the OSAM-1 or Leo Knight.  It is designed to be as small and light as possible while achieving all construction objectives.  It features two friendly arms with robotic hands and potentially a third docking arm.  The craft is capable of delicate work like electronics. This ship would remain near the station.  It is not a speed demon. This version uses two ion thrusters positioned on opposite sides.  It allows for a full scope of movement and negates the need for RCS Thrusters.  It also allows for a very long duty cycle.  It could have the ability to recharge off the station’s power supply or be tethered with no battery to the station to avoid costs.  It might be possible to use a cybernetic human hand that can be interfaced with an actual human using teleoperation or run automatically following a closely monitored program.  The ship could potentially be operated by gloves using midi with enhanced laser range finding data controlled from the ground.  This ship requires large reaction wheels for quick maneuverability and to compensate for the movement of the arms.  It would be capable of hitching a ride on other craft if necessary.

Project Class: ES

Construction EVA Kerbal:

Kmass: 4.3t This ship is the latest iteration of the KCC Kerbal Construction Craft.  The main issue was that the craft didn’t have enough ballast for the arms.  When the arms moved, the vessel moved to compensate for the motion.  The solution was to put reaction Wheels at the end of trusses around the outside of the ship, which allows the craft to maintain position while the arms do their work.  The decentralized stability allows a greater ability to service spaceships and do construction.

MSM:  MSM-1:  Manned Service Module.  The premise is to launch a space shuttle that doesn’t come down.  It focuses on the service bay element and functions as an extended crewed service module.  It doesn’t have wings.  It doesn’t have a heat shield.  It does have extra-large reaction wheels and RCS thrusters for positioning.  It has a robotic arm.  It has an unpressurized workspace and a pressurized living space.  This particular module is the most compatible with the ISS and other space station projects currently in development.

Kerbal recently released their newest update: “Some assembly required.”  It allows kerbal space engineers to move and install some small parts.  Those brave space engineers can only do work when they EVA (get into a spacesuit and manually move the parts themselves).  The game is relatively limited, and the bay is built for much larger projects.  Let us hope this is a failure of the game, not the project.  This module does not have wings. It uses detachable engines with a docking port end.  The other side is a rather large engineering habitation complex.  There is a nicely tucked robot arm on the side.  The other side has ladders and several hard points where an astronaut engineer can attach a carabiner.  An external control system uses petals and joysticks to manually control the arm and other equipment.  There is also a track down the middle of the bay with a grabbing component, as well as ample batteries and storage bays.

MSV: This is a mockup of DARPA Project Phoenix.  It was a manned service vehicle for ISRU repair and refueling.  Not much is publicly available concerning project Phoenix.  It could be because of a lack of funding or security classification.  There is a small chance that a military MSV does exist.  A few other projects are suited for the task, such as Genesis Aerospace’s SPS, A Single Person Spacecraft designed for extended EVAs.

MSV Kerbal

Kmass: 14t This is another non-functioning kerbal spacecraft.  It has no use in the game, but it is designed to be effective if it were an actual spacecraft.  It features four robotic arms to assist in an array of functions, as well as a conveniently located airlock on the top.  It is a manned spacecraft. As such, there are plenty of lights for illumination while working.  There are even lights on the robot arms.   It has space for two crewmembers and an EVA hatch on the top of the spacecraft.  Just in case they have to get out and push.  Just kidding, you can mount a kerbal on a robot arm and allow for safe space construction and repair without worrying about getting lost in space.

Improvements And Add Onʼs:

 At the ESA open day 2019, an exhibit featured new techniques to capture space junk (for de-orbiting, not reuse). They focused on three different methods. They all focus on larger pieces of debris because they are easier to work with.

1 – A robot arm has problems because often the debris is spinning very fast, and the robotic arm has to match using a synchronized motion. However, it is something we can do and has the advantage of a solid, stable attachment.

2 – The second solution uses a net with balls to capture debris. It is untested. There are issues with maneuverability. It would also create potential problems when trying to berth into the robotics bay using a robotic arm.

3 – A Harpoon that can impale space junk and drag it.  The test performed magnificently.  However, there is a chance that the Kinetic impact will create smaller pieces of space debris.

None of these solutions are optimal, and there are several other solutions mentioned below that we think will work better for salvage operations as opposed to de-orbit operations.

Some spacecraft, such as Restore-L (OSAM), can mount a vast array of tools.  Here is a list of existing and prospective tools for use or deployment on salvage spacecraft.  

Honeybee Robotics designed the UGA universal Gripper anchor, The SGT Satlet gripper tool, and other useful things for use with an RSV.

Painting and surface adhesion: we would want the ability to apply coatings of a thin layer of aluminum or other materials to components and spacecraft., if only just to create hardpoints for capture.

Salvage craft could benefit from external Velcro strips for holding quick-change tools in place or temporarily mounting on.

In addition to the normal suite of sensors and cameras, spacecraft that have missions involving Radioactive debris would need to be equipped with Geiger counters for detecting space radiation and contamination, as well as locating salvageable radioactive components. 

Tethers Unlimited has created a de-orbit capture tape.  It is just a bunch of strips of tape that stick to anything. It has the amazing ability to capture objects in rotation. 

Work is being done on tools that allow heat and cold transfer for welding.  A cold welder, laser welder, or electron beam welder can work without an oxidizer or flame. They feature touch sensing and seam tracking.  If the process is done inside the station, we might be able to do ultrasonic friction welding for plastics in a Nitrogen environment.  

– – – – – – – – – – – – – – – – – – – 

I Get around – Space Salvaging Maneuvers: 

Speed limit:  The proposed station speed limit is 0.2m/s within a 1000-meter radius of the farthest outward-facing parts.  The speed limit would be 1m/s ti target for a 10km radius; Walking speed.

I will probably never be an astrophysicist.  That said, I would like to list some of the more odd and advanced techniques for saving Delta-V while doing low Earth orbit salvage operations.

The most important element of space salvaging is relative proximity operations.  RPO.  It is the dangerous and sensitive element of Space salvaging.  First, you get within 1KM 1000 meters.  You slow down to 0.1 M/S and work out how best to make the final approach.

Everyone who plays Kerbal Space Program knows how to do a basic Hohmann transfer.  The transfer is a simple and efficient double burn to change an orbit from lower to higher or reverse.  The Hohmann transfer is very efficient, but we would like to explore some of the more advanced methods for moving debris. 

In a standard salvage operation,  you burn at periapsis to extend out the orbit to a point where you can get very close to the debris, then burn to zero m/s relative to the target.  When your speed and orbit match the object in question, you can close in for RPO and a rendezvous. 

Period time:  A Period is one single rotation around the Earth.  From playing Kerbal, I know it is cheaper to rendezvous with other objects in space in similar orbits by getting near the object with a 0-degree inclination difference. Several orbit periods later, the objects enter relative proximity.  At this point, you match speeds, then burn toward the object.  In most cases, more time spent orbiting means less fuel it will cost in the long run.

Several little tricks can lower fuel costs to a degree, such as burning to where the object will be, not where it is, or entering an orbit slightly higher or lower than the other object depending on if it is in front or behind you, which reduces the number of orbits before an intersection point occurs.  

Molniya orbit is an eccentric orbit that goes from low Earth orbit to medium Earth orbit.  It is used for communications and spy satellites. It can also be used for orbital transfers.  When the object reaches its apex, it moves significantly slower than at its periapsis.  A single satellite can provide a signal for 75% of its orbital period.  They can be used in pairs to communicate continuously to a fixed point.  The most fuel-efficient way to intercept, rendezvous, and retro burn to match speeds at the object’s periapsis.  Molniya is the Russian word for lightning.

Tundra orbit is a figure 8 type orbit also with a high eccentricity.  It has the advantage of orbiting exactly one day per orbital period, allowing it to maintain position over a single spot.  They are used to service high-altitude regions.    They can be salvaged by matching speeds just before the satellite goes into its figure 8.  This would be the most efficient use of fuel.

Tethers Unlimited (ARKA)  has claimed to have an electrical tether that allows a change of inclination for free, allowing movement to a polar orbit and eventually reversing direction completely without expending fuel.  It is brilliant. However, this method does not allow for eccentricity or velocity changes.  The apoapsis and periapsis stay the same while the inclination changes.  Also, it is yet to be determined how long and heavy that tether would be.

Depending on the station location, some objects are more expensive to salvage.  Some spy satellites and all Israeli satellites are launched in a clockwise orbit.  Most objects in space are traveling in a counter-clockwise orbit.  Anything traveling west (clockwise) might be close to impossible.  (I was able to find ways in KSP by using a  translunar injection and gravity assist from the mun to reverse orbital direction 180 degree inclination to -180 degrees)   The fuel cost of changing inclination is expensive.  It is important to know where and when to burn.  The amount of fuel it would take to go from a polar orbit of -69 degrees to a polar orbit of +69 degrees would cost %100 of the fuel with hypergolics.  

Lining up the shot:  We might be able to use small ships for moving debris into a specific orbit.  Somewhere convenient for a future pickup.  Not quite a low earth graveyard orbit; more like putting trash on the curb so the garbage man can pick it up.  This Orbit would be similar to the station position and allow for an easy multi-mission salvage operation in one run with a larger ship.

Booeys and Dinghies:  Homing beacons and small, slow-moving “safe” docking craft.  The concept of creating a safe harbor.  The Booey would enable a safe place to enter into proximity to the station without causing unnecessary risk.  The dinghy spacecraft would move the debris from the Booey to the Station slowly and safely.

In some instances, provided we build a proper propulsion system on the station, we could move the station to the space junk rather than bring the space junk to the station.  The station would put itself into the optimal orbit for several salvage operations at once.  When the salvage missions are complete, the station will move to a more relevant inclination/altitude. 

One of the advantages of low Earth orbit is the ability to airbrake.  Air braking is when you use the atmosphere to create frictional drag and slow down.  It can also be used to circularize orbits and match speeds.   Normally in space, craft have to expend Delta-V (fuel)  to slow down or change direction.  Our project will, in some cases, have the ability to slow down for free.   Aerobraking can also be used for orbital correction and maneuvering. 

The Swooping Crane:  An original term for a deorbit maneuver where the periapsis is lowered to an altitude where air friction can finish the process.  The de-orbiter releases the space junk.  Afterward, the de-orbiter does a one-half orbit back to apoapsis and burns back into a stable orbit.  It can work on more than one piece of debris without sacrificing itself. 

Ion Engines: There are several issues doing orbital maneuvers with ion engines in low Earth orbit. Ion engines require a great deal of power.  The Earth casts a shadow.  The closer to Earth and lower the angle, the longer an object in low Earth orbit is in the dark.  Solar panels do not work without sunlight so the spacecraft has to run on batteries which are heavy.  The amount of energy Ion thrusters need means too much weight in batteries.  The lower your orbit, the faster you move, and the less time you have to do efficient burns.  Ion Thrusters are efficient, but they are not fast.   They have a low force of thrust (Kilonewtons) or, in American English, a very low 0-60 Mph.  The higher orbital speeds create limited windows for efficient burns.  The lack of power generation, low speeds, and limited burn windows create serious issues transporting salvage, especially after the weight increase on the return trip.  Sometimes, after a piece of salvage is picked up, the mission is still possible, but the return time shifts from hours to years.

One fun element of the project is the number of potential missions. We would get much better with low-Earth activities in space. The vast scope of the project could also potentially be used to create public interest. We need to include as many people as possible.  One could easily imagine many ordinary people trying to work out the orbital mechanics in a simulator such as Kerbal space program.

Station Docking Procedure with Salvage:

The salvage craft gets within 500m of the station and matches speeds.  It is effectively going 0.0 m/s in relation to the station.  The station uses its big reaction wheels to line up the robotics bay located on the top of the station to the salvage craft.  The salvage craft lines up with the robotics bay on the Station.  This action protects all station elements except the armored top from accidents.  The craft then proceeds at 0.2 m/s or less toward the robotics bay.   At 5m, the salvage craft does a quick retrograde burn and brings the velocity relative to the target back to 0.0. m/s.   The robotic arm reaches up from the robotics bay and connects to the collected space debris.  The salvage craft detaches from the space debris and proceeds to the next pickup.  The robotic arm then guides the debris into the robotics bay.

Cleanup Order of Operations:  

[large object salvage →  medium object salvage →  Small object salvage → fine particle collection]

The first capture and salvage missions will likely be objects in low Earth equatorial orbit, as they will require the least fuel for capture and return.

Salvaging Fuel:

Some fuels are made for use in space, such as Hydrazine and monopropellant, as well as Xenon, Argon, and Krypton, for IonThrusters. These are fuels that don’t burn off when in long-duration space conditions and could be potentially salvaged.  Some of these fuel tanks are small enough that we might be able to pull the whole tank off for use as a complete component on another spaceship.

Fuels that don’t boil off:
Monopropellant.
Hydrazine.
Noble gasses.

Unfortunately, some fuels do boil off in space.  Most first-stage boosters and many second-stage boosters use liquid oxygen, which needs to be supercooled.  There might be some chance to harvest these fuels from the boosters as a gas and then cool it back down.  In some cases, these become critical salvage missions. If there is too much fuel left in a booster and if it expands enough, the booster ruptures and even potentially explodes, creating a much more difficult salvage involving many more moving parts.

Fuels that do boil off
Liquid Oxygen (oxidizer)
Liquid Nitrogen 

Alternately, sometimes fuel freezes.  More than one spacecraft or satellite has succumbed to its fuel freezing, rendering the craft inoperational.  It would be wise to incorporate some way of heating frozen monopropellant.

Common Satellite Failure Scenarios:

Out of main engine fuel.
Communications issues.
Battery Issues and or loss of power.
Failure to deploy solar panels.
Solar panel degradation due to solar radiation and atomic Oxygen.
Accidental Cold welding.
Frozen monopropellant prevents positioning.
When reaction wheels fail the spacecraft goes into a permanent spin.
Glue melt

– – – – – – – – – – – – – – – – – – – 

The Station Overview:

Station for Servicing And Recycling: This unmanned station is the primary focus of the project.  It is the big Kahuna.  The accountant has a heart attack. The scientist says no way.  The engineers groan. The analyst gives low odds, and the blogger podcast person says the year 2500.  We are going to prove them all wrong.  

Main Station Kerbal:

Kmass: 400+t The most important takeaway from the construction of this station was standardization.  It is big with lots of moving parts.  The robot arms need housings. Else, they flail around.  Mass is a huge factor. The heavier the station, the less it rolls.  If it rolls too much or cannot maneuver.  It is impossible to dock.  So later versions have a structural truss on the bottom with large reaction wheels.

The station has to be efficient and completely automated.  On completion, it would allow us to manufacture semi-complex parts and structures from metals and plastic. One advantage is that we would have access to the highest quality scrap metal ever produced.

The A.R.R.M.S. space factory is a complex system.  It will consist of several modules with several functions. The station’s most extensive module is the robotic work bay. In addition to assembly and disassembly, the robots will do much of the hard sorting work in the ‘drydock.’

The next component is a sophisticated sorting module.  We need to be extra careful to maintain the highest feedstock purity. If the purity is high enough, aluminum and plastic do not need an additional thermal process, and the resulting end product is better.

After the big sort.  We start the industrial process. The first step consists of an industrial-grade shredder capable of shredding just about anything.  This module might also include a crusher, similar to a mortar and pestle, and a fine grinder.  It also includes an additional post-shred sorting module.

The next three modules on the production line work in tandem.  The furnace, aka smelter, and crucible module.  It mixes metals, makes alloys, and incinerates shredded carbon fiber, plastic, and other materials to make fuel.  One side of the smelter is the refinery which separates gasses from the incineration process and makes them into fuel.  After the refinery.  There is a potential fourth integrated module.  The propulsion module, nicknamed F.A.R.T, uses excess gasses and industrial outgassing to make small orbital changes.  There are suggestions in the proposal that do not require any of these modules.

Running factory equipment will require an immense amount of energy.  Thankfully, solar panels keep getting better and better.  The current solar array on the ISS has enough power for 40 households.  We can expand and supplement the power grid with salvaged solar panels.    Another concept is to build a small hydrogen power plant using waste-to-power concepts.  It would run off of hydrogen supplied by the refinery.  If a hydrogen plant fits in a car, it fits in a station.

The structural truss is located below the robotics work bay.  It features power and heat dissipation elements of the station.  The truss consists of an ELC logistics platform mounted to a Z1 truss, a 2nd and 3rd ELC platform for the power systems and factory, a robotic arm, and perhaps an alternate system for moving materials and components from module to module.

Our ability to recycle and reuse could translate into a giant station.  Eventually, we will have ample construction material and the ability to use it. However, it doesn’t have to start as a colossus.  Perhaps manufacturing elements can be done using micro-factory concepts. Think small.  Blender-sized, Toaster Oven-sized, Peppermill-sized.  We donʼt need to recycle 33,000 tons of aluminum per day.  Recycling 0.8 tons per day is more than enough to work with.   It is, in fact, our target goal.

Aluminum and plastic are easier because they can be recycled without additives. However, there is no reason why we cannot also process copper, lead, gold, silver, titanium, steel, or anything else. However, it will require further advances in 3-D printing.  New manufacturing processes or the expensive implementation of more traditional equipment would be heavy with “astronomical” launch costs.  We are betting that additive manufacturing allows us to do things at a more astronominal cost.

There is a great deal of high-grade nuclear material in low-Earth-orbit.  It might be possible to also use a small nuclear reactor like KRUSTY with said weapons-grade nuclear material.

Saving money by not breathing:  We all love oxygen.  Heck, we even need it to live.  The truth is, it is an amazing thing that life would require such a toxic thing in nature.  Oxygen is explosive, It is corrosive, and frankly, it gets everywhere and bonds to everything.  If it weren’t for good ole Nitrogen, which is mostly inert, we would be living on a big fireball.  I am trying to get at that human spaceflight is a fantastic feat.  It is, in fact, absolutely insane.  The simple fact remains, robotic factories aren’t safe for humans, even back on Earth.  Factories, in general, are dangerous.  The ship scrapping industry in India is one of the most hazardous jobs on the planet.  Oxygen isn’t safe to pressurize a space factory, so we remove humans and Oxygen from the equation.  Yes, to cut costs for sure, but primarily out of necessity.

There are a few pressurized components.  The closed-loop pneumatic tube transport and storage system takes maximum advantage of atmospheric pressure.  However, it will not carry pressure unless the system is in use.  There might be other closed-loop pressurized environments in some of the workstations in the robotics bay.  Keeping as much of the station unpressurized prevents problems and costs less.

Not involving humans will also speed up the development process of the project.  We can launch easier and quicker.  The risk is reduced.  We don’t have to worry about G-Forces as much.  There is no life support system.  We do not have to provide food and other human-related services.

How does it work? 

Disassembly, small piece shredding, sorting, smelting, fine powder shredding, processing, printing.  Satellites and craft would be safely disassembled in the maintenance bay. The parts would be sorted and broken into palatable pieces like material composition. Small pieces would be sorted again using several analysis tools. Nonconforming material would be sent back to the repair bay for proper classification and or storage. Conforming material would be melted down to remove any other impurities. Impurities would be cleaned from the smelter/furnace for slag storage. That material would be shredded again into a fine powder for processing in the 3d printer.  The factory would be set up to recycle one material at a time.  

This chart is outdated and has missing components.  

Scan > clean > index > disassemble > Sort (robotics bay) > shred > sort again > melt > shred again > clean (Recycling station) = final product. 

(alternate) Sort (robotics bay) > shred > Incinerate > Refine Into Gas = final product. 

Bay Actions:  Repair, Restore, Assemble, De-fuel, Refuel, Recharge 

Module layout:  

The rocket booster converted into the workshop is the largest component by far.  Consider it the top with the bay doors facing up.  There is a docking port on either side of the rocket booster.  These docking ports (forward and aft) are connected to reinforced materials and fuel storage modules to act as armor, with additional docking ports on the top for salvage spacecraft.  The sorting and shredding module is integrated into the aft materials storage module, whereas the forward storage module is augmented with additional fuel storage. 

There is a structural support truss below the work bay.  It has several large reaction wheels.  There are solar and heat radiation panels pointed downward.    It, too, has docking ports fore and aft as well.  The factory module is connected to the aft docking port with tubes extending upward into one of the materials storage bays.    The docking port’s position allows for safe docking and berthing procedures.    

Alternate Station names: Osiris, Horus, Freyja, Hanhepi, Chimalma, Juno, Khrystos, Lono, Xipetotec, Zalmoxis, Lazarus, or perhaps Tannhauser gate.  I particularly like Terrapin station.  Until we come up with a fancy name, we will call it A.R.R.M.S. (Automated, Recycling, Repair, and Manufacturing Station).  Station Spirit Animal: Worm. 

STATION SUB-SYSTEMS:

DRYDOCK Repair, Maintenance, Assembly, And Disassembly Module: (first project)

(Remediation) This stand-alone enclosed environment for complex refitting of spaceships and satellites would consist of several robot arms of different sizes as well as an array of various robots and robot workstations.

The Hermit Crab:  Around the ocean, there are almost 800 hermit crab species.  The hermit crab searches for a shell, adopts it, and makes the shell its home.  This mission’s premise is a reimagined version of Van Braunʼs idea for a “wet” habitat.   The idea was to build a crewed station built within a rocket casing.  It was called a wet lab and was the original design for Skylab. Thankfully there have been giant leaps in robotics since the 1960ʼs. This element will be uncrewed and unpressurized. It makes phase 1 much more straightforward, safer, and cheaper than the initial proposal for Skylab.  In the most simple terms, this is a robotics servicing and repair lab in space.

This module is designed to function by itself, as outlined in mission 1. One other function of the module is disassembly.  The robots will cut down things that will be recycled into dimensions relative to the scale of the shredder while keeping material purity in mind. 

This module has large double bay doors, such as those used on the Space Shuttle, except larger. As on the shuttle.  These doors are similar to bomb bay doors on larger military aircraft.

Other examples might be more relevant.  There are submarine salvage and repair ships such as the double-hulled Pidgeon class (ASR-21) or the CIA’s favorite fake drilling ship like the Glomar Explorer.  Russia is still operating the 100+ year-old Russian Submarine salvage ship Kommuna (formerly the Volkhov).  All of these Vessels are double-hulled with bay doors on the bottom and a big horizontal crane-type thing. Unlike bombers, these doors are built specifically with servicing in mind.

Spacecraft would enter and exit the overhead bay doors while berthed to a robotic arm.  These bay doors would be powered by four independent motors mounted on the corners.  The bay would hopefully be made from a Saturn 5 rocket casing and be big enough to accommodate almost anything in space at present.  The size of the bay depends on which rocket casings are easily available.

With the doors closed, the bay serves as an enclosed space in the station for repair robots to safely retool, refuel, service disassemble, and manufacture spacecraft.

This module includes a linear hydraulic track system on the floor to move big things around and keep them stable.  It also features a circular hydraulic track system mounted inside the bay on the forward side that rotates and spins to allow access to all sides of the craft being serviced or built while keeping the object stable at all times.

Over time elements of the docking bay, such as the doors, could be reinforced with hardened coatings.  Steel I Beams fore to aft can be added for further reinforcement and to create mounting hardpoints.   The bay could also be reinforced with hydraulic shocks, which brace the connection to the rest of the station, mitigating low-velocity docking disasters.  These same additions could also prevent docking or procession issues caused by the vibration of the manufacturing process.

Once we have a baseline technique, it would not be hard to add a second repair bay using the same methods.  We can also use an inflatable module for additional storage or large-scale external construction.

Concerns: Liquid transfer, cryogenic fuels, storage and recycling, dust, debris filtering, vibration and procession, temperature, pressure seals, radioactive materials, making sure debris does not escape through open bay doors.

(Update 10/19). NanoRacks has begun working on a project to build new wet labs (manned stations) out of Ukrainian-built rocket boosters. They have signed a contract. A dry lab should be less difficult if NanoRacks can already make a wet lab.

Total Cost: $432,000,000 (as projected in mission 1)
project class: ES

Robotics bay workstations:

The assembly and disassembly process is done by several workstations within the robotics bay. The first workstation is a human-like robot complete with cutting saws, drills, perhaps a cutting and welding laser, cold welder, or electron beam welder.  Another workstation would likely involve a robot more attuned for surgeries equipped with microscopes, spectrometers, and tools like pliers, screwdrivers, tweezers, and toothpicks.  Some workstations could be as simple as a workbench. Others would involve more complex workspaces.
 
Standard Workstation:  An arm could be mounted on or built directly into the workbench.  It provides Jaxa and Gitai’s robotic arm and a general suite of robotics with a dedicated work environment to operate in.

Heavy Workstation: There would be at least one heavy workstation with the microgravity equivalents of power tools for basic (de)construction and assembly tasks.  A Bender (Futurama), roller, sander, Bandsaw, jigsaw, CNC mill, drill press, and maybe even an anvil.  There would also be clamps, wedges, straps, hooks, velcro, and other accessories.  In an enclosed and safe work environment, these workstations might be separated from the main bay.

`Micro Workstation:  The focus of this workstation is electronics.  It features a remotely operated robotic pair of hands and arms in a clean box.  It looks and feels like the NASA equivalent on the ground except with hooks and stands so that work can be done in microgravity.

Finishing Workstation:  Often 3d parts don’t print perfectly.  The main purpose of this workstation is to glue and sand imperfect components into a usable form.  If the component is unfixable, no problem; it is recycled again.

Cataloging Workstation: In addition to testing components, we would want the ability to scan components as 3D objects.  We should already have this data from the ground. It is great, but there will be instances where a salvaged object is unidentified, misidentified, or the data isn’t available.  This component will also allow us to verify existing data.  It would be composed of a Lidar Device for 3-D mapping objects, an X-Ray machine, and a standard high-resolution camera.

Testing Workstation: testing equipment in the robotics bay, such as an electronics Multimeter and oscilloscope. An infrared thermometer for detecting faulty electronic components. 

Hazardous Workstation: An area dedicated to safely testing all salvaged satellite or rocket boosters systems.

Cleanroom Workstation: A clean room workstation where sensitive work can be done safely without affecting anything else in the work bay.  The clean room is a small room connected to the cleaning room with an airlock and the standard pod transportation node in each room.

Cleaning Room Workstation:  The cleaning room could be pressurized or depressurized with nitrogen or argon.  This workstation is meant to remove paint, coatings, exhaust, and any other particles or mostly evaporated fuel that might be stuck to components of the spacecraft/satellite which have been exposed to the elements.  The workstation features a beefed-up ventilation system.  A way of Scrubbing surfaces with liquid CO2 where the CO2 is recycled back into the system (like a professional wet/dry carpet cleaner.

One or two larger workspaces will have an airlock-type door leading back out to the central bay. These allow for moving parts larger than will fit into a pod.  It doesn’t necessarily need to be pressurized.  Airlocks adjoining workspaces and the central space will have an emergency robot arm or other measures to ensure things don’t get stuck in the airlock.

project class: ES

Internal Servicing Robotics Bay Robots:

Robots don’t Sleep: The station can do 24/7/7 construction as long as there is sufficient power.  Ground control will use a combination of preprogrammed actions and Augmented Reality to interface with the robots.  The Robots will also have limited Artificial intelligence and should be able to perform some basic functions without human intervention.  I.e., The ability to ask the robot to disassemble a satellite rather than walking the robot through each step.

Our Tireless workforce will consist of several designs that work for our system.  Almost all internal robots in this section could be mounted on the CanadaArm2 for station repair and construction. (Robot on a stick)  Astronauts have been riding on robotic arms for EVA repair since the dawn of space servicing and construction.  Having the option of an enclosed bay allows us to use robots in space for servicing situations safely. 

GITAI has a series of robots that are made for space.  It feels made for this program, or maybe this program is made for GITAI.  It uses a real-time virtual interface with a human operator. Two arms, no legs. one human hand, one grip hand. It can perform complex tasks like repairs and disassembly.  GITAI uses an array of visual optics.  It was tested in a mock-up version of the ISS at JAXA (Japanese Space Agency). It was also successfully tested in the Bishop airlock on the ISS in 2021.  This test consisted of a single robotic arm that assembled a relatively complex solar panel with precision. This involved aligning and tightening screws and nuts using several different hand attachments. Assembling posts and doing some rather sophisticated wirework.  It could press buttons on a console, flip switches, pull levers, and turn dials.  It can open or close a crew hatch.  In its first incarnation, it looks a bit like a toy I had as a kid called Armitron.  GITAI, however, has plans for much more sophisticated robots.  There is a human interface that allows a user to work remotely with the robot that involves natural movements.  It has been demonstrated working in an auto garage and making sushi (with a human operator).  GITAI is the current favorite for the development of specialized robots and arms in the service bay. 

“We believe that a combination of 95% autonomous control and 5% remote judgment and remote operation is the most efficient way to work. In this ISS demonstration, all the work was performed with 99% autonomous control and 1% remote decision-making. However, in actual operations on the ISS, irregular tasks will occur that cannot be handled by autonomous control. We believe that such irregular tasks should be handled by remote control from the ground, so we believe that the final ratio of about 5% remote judgment and remote control will be the most efficient.“ -Sho Nakanose from GITAI
Project Class: NEN
Link: https://gitai.tech/

Fanuc builds industrial robots widely used for repetitive tasks in the industrial sector.  They are pretty much the industry standard.  They can arc and spot weld, mill, assemble, machine, cut, remove material, paint, etc. They are also usually enormous and heavy.  We could probably use some sort of torq wrench and drill arm robot  (with a potential secondary arm to hold and capture bolts, nuts, screws, etc.).  Perhaps they could build some complete workstations like Daisy.  

project class: EEC
Link: www.fanucamerica.com

Daisy is an automated Apple iPhone recycling lab.  While more of a micro-factory than a robot., it can fully disassemble and recycle over 20 phones an hour.  Daisy is about the size of a kitchen.  This makes it on the larger side of our current ability to launch things into space.  Not impossible, but likely expensive.  Several components could be easily integrated to help with disassembly.  Apple has made Daisy open source.

Project class: EEC
Link: www.apple.com
Link: https://youtu.be/E7WQ1tdxSqI

Boston Dynamics Bipedal Atlas robot, strong enough for the military but PH balanced for Google. It stands at 1.8 meters. It could be outfitted with magnetic shoes.  This 2 million dollar robot is an obvious choice.  Since this proposal was first submitted, Atlas has been improved several times.  However, there is no artificial intelligence involved.  Its moves are all pre-programmed by a human using keyframing.  Google originally owned Boston Dynamics, then sold it to Japan’s Softbank, and it is now owned by the carmaker Hyundai. 

Project class: NEN
Weight: 80kg
Link: https://www.bostondynamics.com/atlas

The Russian biped robot Fedor (Theodore) (Final Experimental Demonstration Object Research or Skybot F-850) can perform basic tasks.  It has human-like hands. It was deployed to the International Space Station in August 2019 and successfully tested in space.  It can press buttons and turn levers.  It was able to successfully connect and repair cables in zero-G.  It also successfully used a drill and a wrench during its one-week tenure at the ISS.  However, some astronauts were creeped out by its ability to aim the drill at them.  It also had a peculiar response to the crew putting their hands up.  It has a serious artificial intelligence component.  There is a legless version that is more applicable to space called Alyosha.  Perhaps it is more space oriented and has an augmented target-tracking ability that doesn’t involve firearms.

weight: 158kg 
project class: NEN
Link: http://en.mchs.ru/

There are several surgery robots that can be retooled for use in space on circuit boards.  For instance, Devinci is a medical surgery robot built for precision surgeries.  It has an arsenal of vision, cutting, gripping, and stapling tools.  Similar robots might be able to assist with micro-electronics and circuit boards.

Project class: EEC
Cost: $2,000,000
Link: https://www.intuitive.com/en-us/products-and-services/da-vinci

Guardian GT exoskeleton is a remotely operated robot custom-built for demanding tasks like nuclear disaster recovery. The operator stands in a robot exoskeleton. The robot moves like the operator. It has a head with eyes that rotate with the operator. It can grip, cut,  press, drill, crush, etc.  While the chassis sits on treads, there is likely a better solution for space.  This robot has a helpful human interface.

Project class: EEC 
Link: https://www.sarcos.com/products/guardian-gt/use-cases/use-case-guardian-gt/

Samsung Bot Handy:  This personal service robot debuted in 2021.  It is a one-armed bandit that can do dishes, pour wine, and do numerous other household tasks.  

Project Class EEC
LInk: www.samsung.com

Spot, a mini four-legged friend: Spot mini (DogBot) doesn’t sound inherently helpful at first. However, it has a robot chicken head that does interesting things where the body can move (around things), and the head (arm) stays in the same place. This could allow for a stable cam video relay.  Spot is available to the civilian market as of 2021 for $75000.

Project class: EEC 
Link: https://www.bostondynamics.com/spot

Stanfordʼs Ocean 1 Robot humanoid in shape but made for deep-sea operation on offshore oil rigs and such. It might be easily translatable.  It has two humanlike arms with gripper hands.  It has propellers instead of legs, which might easily be replaced with a space propulsion system. Alternatively, they could be left as propellers in an enclosed nitrogen environment.  Space scuba.

Project class: EEC 
Link: https://cs.stanford.edu/group/manips/ocean-one.html

Hadrian X Is an extensive concrete brick construction system.  It can print and place bricks and can fabricate them on-site. While not particularly relevant, it is an exciting idea. A similar machine would be needed to build trusses and other large structural components.  This is the premise for Archnaut Osam-2. 

Link: www.fbr.com.au/view/hadrian-x  

The Redwire Regolith Print (RRP): Launched to the ISS on August 10th, 2021.  It Is meant to operate like the Hadrian X but on the moon, using lunar regolith (dirt)  to build structures.  Redwire is an interesting company.  They are New, founded in 2020.  They are owned by the parent group AE industrial.  They seem to have a lot of capital.   They Bought Made in Space and Techshot immediately.  They currently own most ISRU projects that have been actively applied to the ISS.  

Link www.redwirespace.com

Andros Nomad: A bomb disposal uncrewed ground vehicle by Northrop Grumman shows promise.  It has some of the tools necessary for assembly and disassembly.  The treads would have to be removed.  It is mentioned here because it has an effective functional human interface.  If it can disarm a bomb, it can also probably take apart a CubeSat.  

Project class: EEC

Link: www.northropgrumman.com

Teslabot:  This humanoid robot is 5’8, weighs 125 pounds, and has ten-fingered hands.  Elon Musk has an interesting design process.  His team is amazing at taking out any moving parts that aren’t essential.  They have developed a fairly complex artificial intelligence and camera array to self-drive their cars.  The robot uses the same system.  Their choice to make it humanoid lends itself to some sort of future project.  

Link: www.Tesla.com

Hondaʼs ASIMO bipedal bot with full hands already looks like an astronaut.  It is built to be human-friendly.  The hands are well done.  It can do things like shake your hand.  Its human friendliness makes it suitable for the ISS.  Although somewhat less suited as a space factory worker than GITAI.  Unfortunately, the ASIMO project was canceled in early 2021.

Project class: EEC
Height: 130cm
Weight:  50kg
Link: https://asimo.honda.com

King Louie human-shaped, inflatable human-friendly soft robots have a space advantage. They can be deflated for compact and lightweight shipping.  While we don’t need human-friendly robots for this project, Having the stay puft marshmallow man on your side never hurts.  The project is NASA-funded.

Project class: NEN 

Link: https://news.byu.edu/news/byu-engineering-making-more-people-friendly-robot

Some of these right stuff robots would have to be modified for use in space, including adhesion changes, and then reprogrammed to work within new microgravity parameters. 

Alternate Robots: (that don’t exist) 

I imagine six or eight-legged armed robots with interchangeable utility movement and repair arms. Or robotic spiders on Velcro spiderwebs. I should also probably mention R2D2 and C3PO as well.  Here are two deemed essential robots that don’t exist yet.

Project Class: ES.

Mini Crawler Maintenance robot: A smaller in-station battery-operated crawler version would be deployed on the unmanned station to travel through the pneumatic tubes, gas, and fluid lines.  It would use tiny emergency repair corridors and open special maintenance hatches for internal station repair.  Perhaps they would be the size of a large beetle.  However, Much smaller than Paul Macartney.  Since it operates in zero gravity, it would also have the ability to jump, hover, and latch on. They would be small.  They would have a lightweight propulsion system for emergencies. 

Project class: ES

Mr. Cleanbot2000: A robot made for cleaning up parts that will be reused in completion, removal of residue from rocket boosters, with a vacuum suction arm and wide-angle suction roller with super sticky properties.  It might also work as the station Janitor, cleaning up industrial messes.  Think Roomba (little autonomous vacuum cleaner) in space.  The Giddel toilet cleaning robot shows promise. Some of these small ships would live in the repair bay.  It could also clean via vaporization. Now with a fresh lemon scent.

Project class: ES

Other Space adjustments: Pogo stick bottoms for robots with a monopod type extendable chassis and potentially a small form factor magnetic tread bottom and or electromagnetic foot mount hard points for the robotics bay.  They are only active when in use.

External Transportation, Construction, and Assembly: 

Kmass: NA Another kerbal design for aesthetics only.  It is supposed to work with several rails mounted on the “bottom” of the station.  Robotic arms, as well as transport containers, can run on the same system of rails.

The ISS uses the MBS (The Mobile Base System) part of the MSS(mobile servicing system).  These are rails that run the length of the main truss.  The CanadaArm moves up and down the track and allows for equipment, components, and even modules to be transported from one side of the station to the other. An external rail transport system could be a good thing.  It would provide an alternate, although limited, way to move pods around the station, at least on one line but isn’t necessary.  

There have been serious advances in robotic arms for space use in the past few years.  One of the advances is the ability for the arms to attach to the station from either side of the arm.  This allows the arms to roam freely around the station as long as there is a hard point for the arm to attach to.  Running a rail the length of the station does provide an excellent array of hardpoints for a robotic arm, but again is not necessary.

There is an internal transportation system using pneumatic tubes.  If we manufacture an object larger than can fit in the tubes, it will have to move around the station externally using robotic arms.

Kerbal Robotic Arm (KRM):

Kmass: 4.8tRobotic arms in Kerbal tend to flap everywhere and aren’t used very much because of this.  But they are still possible.  Here is an example.  It folds nicely into a circular container for safe storage and to prevent the arm from drifting out of place.   The truss-like container also rotates up to 20 degrees in both directions on the x-axis.   Allowing the arm to reach into the workshop at any location.  They also provide a safe and easy way to berth incoming disabled spacecraft rather than dock them.   I am unsure how the CanadaArm or Strella function exactly on the ISS.  Somehow, I don’t think they get the same used car dealership wacky wavy arm guy effect that I get.  However, in kerbal, like many things, if you build without structural integrity.  The space Kraken rears its ugly head and commences with rapid unscheduled disassembly.    The arm in the top photo is good.  The two arms in the bottom photo have no chance and will eventually get tangled with each other and the station, eventually leading to total destruction.    The truss segment also makes for a decent spaceship.  Notice the angle of approach.  There are no solar panels, heatsinks, batteries, or other components for other craft to crash into.  The delicate components are inside the truss-like container for the arm.

CanadaArm and CanadaArm2: (SSRMS) Space station remote manipulator system. It is the gold standard for robotic arms in space.  It is used on the ISS for almost every space construction project.  CanadaArm 1 was used on the space shuttle for a variety of missions, After the space shuttle Columbia accident in 2003.  CanadaArm1 was used to check the heat shield before reentry.   It was used with the Hubble space telescope several times.    It uses a three-wire grapple system that closes around the desired object and retracts.  There is also a  latch mechanism  CanadaArm2 was built and installed for servicing and construction on the ISS.  It was designed by MacDonald, Dettwiler, and Associates. The arm extends out 15.2m.  It can move around the ISS, has been significantly upgraded, and can now move masses of up to 116,000 kg, albeit very slowly.  The arm can be controlled by astronauts in the space station or from ground control.

Project class: NEN 

Weight: 431kg

LINK: https://mdacorporation.com

DEXTRE: SPDM is a Special Purpose Dexterous Manipulator.  It has two arms used on the ISS for repairs, construction, and, more recently, berthing.  It was launched in 2008.  It is deployed from the CanadaArm.  A large multitool for the CanadaArm on the ISS.  It functions as a robotic Swiss army knife with many bolt drivers and other essential construction tools.  The primary tool is a rotary percussive drill with detachable screw bolt heads.  Some consumer drills have a hammer function called an impact drill which is likely built in as well.  There are smaller versions for salvage spacecraft, such as Restore-L.

Weight: 1542 KG 

Cost: $200,000,000 

Project class: NEN

LINK: https://mdacorporation.com

RMS Remote Manipulator Arm:  The Chinese robotic arm is well designed.  It can detach from one end and attach to the other, allowing the arm to move around the station.  The arm can attach to another RMS to make the arm extra long.  It can move modules from the station from docking port to docking port.   It is 10 meters long and can move modules up to 20 tons.    It was launched with the Tianhe on the exterior of the space station module.

Project class: NEN  

Link: http://cnsa.gov.cn/  (link deleted)

ERA European Robotic Arm:  The arm is 11m long and can move up to 8 tons.  It was launched to the ISS aboard the Russian module Nauka in July 2021. It is the basis for the design of the Chinese arm. It can also move hand over hand and around the Russian Module from which it was launched.  This arm replaces the 2 Strela cargo cranes on the Russian modules.

Project class: NEN 

Weight: 630kg

Power 400-800 watts

Link: https://www.spaceoffice.nl/en/

Kraken: By Tethers Unlimited. A robotic arm designed for small spacecraft to perform assembly tasks, such as the dragonfly spacecraft deploying its photo array or satellite maintenance. It is 1m. This little robot arm is made for an array of tasks.  While it is a great and functional arm space, it is a horrible name in kerbal.  

Project class: NEN

Link: www.tethers.com

Strela: This Russian-built cargo crane is currently being used on the ISS for work on the Russian side of the station.  It is not really a robotic arm as much as it is a crane.  There is no elbow-type joint,  but it does do some interesting things.  It allows Astronauts to move up and down the extendable pole, which extends out 14m unfolded. They can tie cargo to the movable steelwork.   There are plans to replace it soon with the ERA (European Robotic Arm).

Project class: NEN 

Link: http://en.roscosmos.ru/

L.A.W. (Longarm worker and docking assistance) Our fictional custom robotic arm is used for berthing satellites and craft into the robotics bay. It is similar to the Strela crane but perhaps longer. 

The longer the arm, the less chance of in-space collisions during the rendezvous process and the more access to docking areas around the rest of the station.  It is hard to determine how often an accident like this might happen, but we predict it will likely occur at least once. An extra arm and an easy installation process can help ensure that there is not too much downtime after an accident.  Or, if nothing else, help with repairs.  

Project class: EEC

Octopus Garden: A ball jointed tentacle arms for close proximity work. It can function as the tip of larger arms or stand-alone. With conical sections instead of square or round sections. 

Project class: ES 

Internal Factory Materials Transportation:

Unlike Factories on Earth, you cannot use gravity or conveyor belts to move objects in microgravity.  The Internal transportation system will have many nodes.   There is at least one dropoff node for every module, and in some cases, several nodes.  For instance, every workstation in the robotics bay would have its own node.

Pneumatic tubes were used extensively from the 50s for mail delivery systems in office buildings before email existed.  They are still used in hospitals to deliver medicine.  Traditionally, Pneumatic tubes are pressurized with air and operate in an open loop system. The air is pumped with fans to generate pressure to move objects based on the creation and dispersion of a vacuum.  The air is dispersed into the local environment.   It doesn’t work for space.  The System has to work in a closed loop, which is possible for sure but has never been done.  The tube system would be pressurized with nitrogen to avoid fires or explosions.  

The system works with a series of switches that determine where the pod will end up in the tube system.  These switches open and close inside the system to change the pressure and force the pod to go where needed.  In many instances, the switches are rotary switches like you would see on a revolver.

The pneumatic tubes might be able to do gas transfers directly by completely emptying a pathway then refilling it completely with nitrogen. 

Maintenance of the pneumatic tubes might not be too difficult.  The tubes themselves should never need maintenance. The pumps that drive the tubes can be located at an easily accessible central location.  Preferably located near the other pumps for the liquid cooling system.

Suppose pneumatic tubes turn out to be problematic. In that case, the internal materials transportation system could function like an electric train system using electromagnetic tracks to propel the pod containers from module to module instead.

Some modules, such as the shredder and furnace,  might require creative last-mile solutions.

Perhaps an eyedropper-like device that uses a tiny air bubble to generate pressure. or a more traditional approach using a turbopump like those used in modern rockets.  Perhaps a curved paddle wheel apparatus that spins at alternating speeds so that the speed change ejects the product into the next compartment.   Another unpressurized solution functions more like a shuffleboard with a retractable element.  The pusher is the width and size of the tube.  It pushes substances down the tube and then retracts again.  Many traditional recycling plants use corkscrews to move materials from one section to another.

project class: ES

Pod Storage and Transportation Container:

The pod needs to be perfect.  It needs to be adaptable, durable, and reliable.  It needs to be an overachiever.  So let us use the German jerry can for inspiration.  The pod needs interfaces for loading up 3D printers with powder or transferring fuel.   The interface is the same on both circular sides.  They are symmetrical.  There are two gas/liquid connectors, one electric power connection, a data connection, and a QR code per circular side.

The round ends are also removable.  In addition,  a hinge on the long end allows the pod to be opened halfway for complete access.  The pod can be pressurized, heated, or cooled as needed. When used for storage, it can maintain ideal conditions indefinitely.  

The jerrycan has a breather tube, so air flows in while liquid flows out.  We adapted the idea by including two valves on each side.  The pod’s fuel valve interface and any two out of four nozzles can be used for pressurization, depressurization, and exhuming contents.  They are designed and positioned in order to be reversible.

The jerrycan has shallow groove slits for rigidity and to hinder and compensate for expansion and contraction.  Another take from the Jerry can, which can be incorporated into the pod, is building the pod in 2 halves with a center weld to prevent damage and help with structural integrity.  If the weld is anywhere else, it creates a potential vulnerability.  The pods are roughly ⅓ of a meter long and 25 centimeters wide.  They should be transparent or at least have a small window so contents can be verified without opening and any problems with the contents can be detected without potential hazard.

The  Pod container also functions as a storage device. Unlike the jerrycan, the pneumatic nature of our transportation system does not allow for square storage containers.  But we need to put some thought into the most efficient way to store them.  Perhaps a honeycomb-like structure would work best for spatial efficiency, easy access, and additional safety.  The lack of Oxygen should allow for the safe storage of hypergolic fuels, such as dry nitrogen. The fuel tanks need to be grounded to prevent electrostatic discharges.  A robotic arm retrieves the correct container when a specific material, alloy, powder, or object is needed. It puts it into the tube transport system to be sent to the proper location.  

Keeping track of alloys with information stored in the storage pod and the central database for redundancy.  The information can be accessed via scan code on the longer side or digital interface on one or both sides.

Somewhere within the network of pneumatic tubes, closer to the robotics bay, there is a pod tester and cleaner to ensure no leaks, purity of material and full function.  If a pod is broken in any way, it is sent to the robotics bay for repair.

The Station cleaning and Station repair robots are designed to fit inside a pod. Or at least small enough to travel along a pod transportation corridor.

The pods can hold gold, silver, steel, aluminum, plastic, and Mylar as a powder for the 3D printers.  The can also contain Water, Oxygen and Liquid Oxygen (LOX), Kerosene (RP-1), Nitrogen, Nitrous Oxide, Nitric Acid, Nitrogen Tetroxide, Hydrogen peroxide, Hydrogen, Helium, Xenon, Argon, Krypton, Hydrazine (hypergolic), Dinitrogen Tetroxide (MMH) and (UDMH), and Ammonia (for Station cooling) and spare and manufactured parts, 

project class: ES 

“Spacegram – Pod delivery service”  The standardized containers would fit into a small specialized spaceship in order to ship things from the station to other locations in space.  It might be possible to instead use a strap-on fuel tank and engine.  This could help with refueling.  It can help with repair when used in conjunction with another spacecraft.  

Example:  We know something is wrong with the satellite, but we don’t know what.  We send a servicing craft to fix it, and discover that it is a broken solar panel.  We could ship a rolled-up solar panel in a pod to the repair craft and satellite in question.  This would save the heavier servicing vessel valuable fuel. 

Cryogenic Fuel storage: Lockheed Martin has been working on a government contract to make cryogenic in-space refueling possible since August 2019.  There was a successful cryogenic fuel transfer on the ISS once around 2017.  (citation needed)

project class: EEC

Nuclear fuel and waste storage:  Work with Nuclear materials might be an unfortunate reality that we will have to deal with at some point.  Radioactive waste would likely require specialized pods designed for the sole purpose of radiation containment.  Plutonium is Likely the most valuable thing we can salvage from the space race at $64,000 per oz.  The second most valuable asset is highly enriched uranium 235 (90%+).  From 1967-1988 the Soviets launched tons of enriched uranium.  Their average was 31.1kg per nuclear-powered satellite.  The internet does not have much information about these early Cosmos edition satellites.  Many of them are missing from launch rosters entirely.  Asking Russia for their old weapons-grade uranium might not go over so well.  Perhaps we could offer the assurance of continued cooperation on space projects in exchange. 
project class: ES 

Sorting module:  

The first and most important sort is done in the drydock by the robots.  They do most of the heavy work.  As the debris is disassembled, parts taken off the satellite are processed and scanned so that we can recreate said part with 3D printers. The robots then sort materials into bins.  When there is enough material of a specific type, that material goes into a more sophisticated sorting machine in order to keep the purity high.  The sorting process would be multi-tiered.  After the initial sort and shred, a second sorting process begins before the materials go to the 3D printers for the additive manufacturing process.   

The most basic and widely developed visual object recognition software is open-source software called TensorFlow visual object detection in python.  It uses machine learning deep learning AI (artificial intelligence). There are several online archives of images for detection training. The largest open-source database is Imagenet.  However, for this project, we would have to build a project-specific database.

Realtime visual object recognition using Ai and machine learning is new tech and absolutely necessary for this project.  Object detection isn’t anywhere near as hard as facial recognition or self-driving software for cars. But, it is still a challenge when applying it to the space industry.

X-Ray sorting: I recently applied for a job with the TSA.  Actually, I passed on the first shot.  Thanks to the years spent working on this document, the reading and writing part was easy.   The other element of the test was more tricky and required some training.   It was the X-ray machine analysis section.  You put your luggage on a conveyor.  It goes through an X-ray machine.  There are all sorts of digital object identification programs.  However, the test forces you to make your own judgments without computer analysis.  The X-ray is slightly flawed in that it compresses a good deal of 3-D information into a two-dimensional image.  However, it is a great start if you want to sort garbage.  Blue objects represent metals, ceramics, and hard plastics.  Green is softer plastic and other inorganic materials.  Orange is cloth, food, herbs, and other organics.  The other factors, shape and size, also play important roles in x-ray image object recognition.  

It doesn’t seem like a far stretch of the imagination to run all the garbage through a TSA X-ray machine with all the DHS (Department of Homeland Security) computational bells and whistles, some of which are open source and available for free.   The data is sent to a series of robot arms that pull specific things off the conveyor and into proper bins.   

Ultimately it should be able to pick out the most conceivable objects.  If an object is unidentifiable, it makes it to the end of the conveyer belt and moves into a pile for further analysis.  If you are recycling specific things such as plastic bottles, the system should work even better.  it would be easy for one robot arm to pull off the hard plastic tops and another to pull the bottle afterward.   

This is all fine and good for a modern American recycling plan which we desperately need, but what about space?

The sorting module would include magnetic separators using eddy currents to remove plastic, rubber, wood, carbon fiber, and all non-ferrous materials. Some recycling plants use gas to push particles of different weights out of a sort.  We could achieve a similar effect if the module were pressurized with Nitrogen.  Another terrestrial technique for sorting that might be useful is a vat of water.  Heavy materials such as lead, copper, and aluminum sink, while lighter materials such as plastic float.  I am not sure how this would work in microgravity. It might require a centrifuge.  Some plants employ skimmers to remove impurities from metals while they are in liquid form.  Other plants use ultrasound in liquid to separate materials.  There are also good old-fashioned screens to separate particles based on size.

The sorting module requires a vast sensor array.  There would be an X-ray, infrared, and laser mechanism for the identification and sorting of different aluminum alloys and other heavy metals.  A short-range mass spectrometer would provide more data on the second sort after the first shred.  It might be possible to use some form of electron microscope to assist with sorting.  Electron microscopes already require a vacuum to operate in. A Geiger counter would help ensure that nothing irradiated or radioactive ends up in the smelter.  The sorting module is a critical technology needed to enable an effective recycling plant back on Earth too.  

Project class: ES 

Cataloging:

The logical next step after sorting.  A database of Space parts.  These parts can be scanned with standard methods, cameras, lidar, and X-rays.  The parts are added to the database as images from all sides and as 3D objects.  More information allows the AI to better detect parts from any angle.  Artificial Intelligence Object recognition systems are not great at guessing or theorizing what a part is, so we must include as many components as possible from as many angles as possible, from partially or fully configured components down to individual elements.  Some of this information could potentially be provided by the space debris client.

Propulsion: (FART) (Factory Activated RCS Thrusters) 

FART is directly linked to the furnace refinery and internal transportation system.  Industrial outgassing from waste gas functions as RCS thrusters.  The FART System uses pneumatic tubes without the pods to transfer the gas to the appropriate Thruster.  The waste gas is heated and compressed at the thruster.  F.A.R.T. is an expensive proposition. While the propulsion system doesn’t require any new scientific breakthroughs, it is a difficult engineering challenge.  These systems need to be developed from scratch.  It is tricky because several complex systems need to be designed to work together.  

A traditional fart is mostly Nitrogen and Methane, both of which can easily be provided by the refinery.  Chances are the station’s farts will be much nastier.  It could be a mix of all sorts of nasty chemicals.  

The gas used for FART would likely be made in batches, with minor adjustments depending on its chemical composition.  It would likely compress, cool, or heat the gas as needed in storage tanks before it expels it.  

The engine would function like a monopropellant RCS Thruster.  It doesnʼt have to be fast or particularly efficient.  The design might resemble the astronaut backpack manned maneuvering units  (MMU).  The Pneumatic tubes might assist in moving large amounts of gasses around the station to the desired thrust module.

The outgassing would not release radioactive gas or waste. F.A.R.T. might qualify as an NPPE Nuclear power and propulsion element and could help dispose of radioactive waste via outgassing. 

The project is called a space station, but it is not stationary.  Just as Mir changed orbits and went to the Salyut, in that famous mission, F.A.R.T. enables the station to avoid getting hit by space junk and make emergency maneuvers.  Given time, it might be possible to slowly fart the station into graveyard orbit past GEO while capturing and recycling space junk along the way.

project class: ES

Option 2, The fully developed option.  We use the Advanced Electric Propulsion System (AEPS) designed for Lop-G. If nothing else could function as a backup system.  It is an Ion Thruster that uses Xenon ionized into plasma.  It might be a decent and more practical intermediate option. 

project class: NEN

If we have the space tug working, we might opt for no propulsion system at all.  The space tug can provide all the thrust we need for minor changes. Wight might still need RCS thrusters to reset the reaction wheels if they saturate.

Power: 

Solar power:  The obvious first choice for power is the ISS IROSA Roll out solar Arrays Built by Boeing.  (deployed to the ISS in August 2021)  They deployed six panels at 22KW X 6 = 132KW (enough to power 40 U.S. homes). These represent the newest and best solar arrays in space yet.   These 40kw solar arrays in space occupy around a hundred square meters of solar panels.  Solar is a good option. However, it doesn’t meet the 24 hours a day operating requirement for some orbits.
Project Class: NEN

The Solar Farm: It likely wouldn’t be too difficult to expand power output by building solar arrays made from salvaged solar panels. Almost every spacecraft and satellite has solar panels, maybe we don’t have to launch as many of them.  We would deploy enough solar panels on the bottom of the truss to start operations.  Hopefully, we can bootstrap more to the station as the project progresses.  Perhaps we would build a structural support pointed downward from the bottom of the truss to facilitate our mismatched solar farm.

project class: EEC 

Nuclear Power:  There is high-purity radioactive fuel in space that should be salvaged.  Using the fuel makes sense if we have to deal with radioactive materials anyway.  The fuel isn’t launched from the ground, eliminating one major problem.  Using nuclear power becomes a better option as you upscale the furnace.  There is a better power ratio using direct heat rather than converting the heat to electricity.  It would allow the station to operate more efficiently in an equatorial orbit where you get x amount of sunlight relative to the distance from the planet.  

The KRUSTY (Kilopower Reactor using Sterling Technology) nuclear plant would provide up to 10 Kilowatts with a single reactor. KRUSTY is the safest nuclear choice, but we might be able to get a higher efficiency than 6% if we bypass the sterling reactor and direct the heat to the smelter without converting it to electricity. The KRUSTY uses a specific form of uranium. Worst case scenario, we can recover uranium from salvaged craft, ship it back to Earth for processing and then send it back to space. The KRUSTY module would be accessible from the outside so as to prevent radioactive material from entering the station from any other location to avoid contamination. A radioactive smelter doesnʼt help us much. The second problem is that the station could require far more output than one KRUSTY can provide. A rough estimate for the station run without alternate power is around four kw. The KRUSTY only provides between one and two kw. It could take as many as four KRUSTY’s to run. 

KRUSTY uses highly enriched uranium at 93% U-235, which is very close to what the US and the USSR used during the space race. Radioisotope thermoelectric generators have a high amount of radioactive material for a relatively low amount of power. Something about Y-11 fuel conversion. This could be a serious problem because I think Y-11 might be liquid uranium 235. Maybe, 

maybe not. 

In December 2020, the Whitehouse issued a memorandum asking NASA to stop using weapons-grade uranium in space.  They decided it could be viewed as weapons proliferation and recognized much of the danger.  Since its adoption, NASA has converted several deep space projects to use radio materials that have not been enriched anywhere near the 90% needed for weapons-grade material.  – Physics Today.

 There are only a handful of engineers capable of working with such a power plant.  Most of them work for the navy and are sworn to secrecy.  Salvaging radioactive materials presents an entire subset of complications.  Lastly, it would make the project unpopular with the public.  It is a major added complication that could be more trouble than worth.

If we go with the nuclear option, it would be the full-fledged nuclear option. One of the products that would be manufactured is nuclear-powered plasma thrusters for large-load interplanetary missions.  One of the decisive factors is the danger of the current nuclear-fueled space debris.  If the danger is low, building the station without any nuclear components would make financial sense.

KRUSTY module = 1800kg 11ft by 5ft. 

project class: NEN 

Waste to power:

 Waste to power is a standard procedure at recycling plants worldwide.  You can incinerate lots of things like wood, plastic, rotten food, and almost anything Carbon-based.  However, most satellites don’t have much in the way of organics.  In space, we have plastic, Carbon-fiber and fiberglass, silicon, kevlar, optical glass, and some of the compounds in hypergolic fuels to work with. If a plastic component has become too brittle and cannot be recycled, It can be broken down into hydrogen and methane via incineration. Similarly, any other organic compounds can be broken down into usable gasses with heat via electrolysis. This would provide Methane and Hydrogen.  Both substances can be used to power and propel the station. However, we would still need an oxidizer, which would have to be shipped up from the ground.  

“We wood if we could”

project class: ES 

Kinetic to power:

Converting the motion of a piece of space debris into energy using a tether and a wheel as part of the capture process.  This is practical in the capture but not at the factory, as the momentum transfer would require counter thrust to maintain orbit.  Perhaps a flywheel such as the one made by amber kinetics could be employed extremely effectively in a zero-gravity environment. 

Project Class: ES

Batteries and Power Management Units:  

With a massive electrical storage system, we can provide power continuously while in the small timeframes that the Earth blocks the sun.  Even if the station operates in an equatorial orbit, we would want lots of batteries for emergencies and for repairing and upgrading the power systems.

Tesla batteries, electric bike batteries, vape batteries, and several other things share the same battery.  It is the 18650 lithium Ion battery.  They have a standard voltage of 3.7v and a maximum capacity of 3500mAh. Tesla has around 8000 of them per car.  I am sure there is a space-hardened version that does exactly the same thing.  We would likely need around 32000 of them, or four Tesla cars worth, to provide a fair amount of power.

Batteries hate cold.  They don’t conduct energy as well.  It might not be a bad idea to use them as insulators for the phosphorus thermal piping or in some other key location where they can soak up some but not too much heat.

Just like solar panels, batteries are present on most intact space debris.   We might be able to make a battery farm from salvaged and refurbished batteries, similar to the solar panel farm mentioned above.  

Cooling and Thermal Control: 

How kool? Kerbal Kool:

Kmass: 400+ tonsThis version of the Station has large thermal radiators that extend down over all the sensitive components.   They function as a solar shade as well as their designated heat-radiating purpose.

There is no air in space, so convection cooling doesn’t work, or at least in the same way.  There are active controls and passive thermal controls.  Passive works by radiating heat as infrared light. Using  MLI (multi-layer insulation), Paints, and blankets.  Active components are isothermal and should operate at as high temperatures as possible.  Heat transfer is measured in wattage.  Thermal panels are usually aluminum honeycomb or straight aluminum.

The sun emits heat at 1358 watts per meter squared in space.  It is four times hotter in low Earth orbit than on the surface.  However, the outside temperature is extremely low due to the lack of particle density.  Some elements of the station will need to maintain a stable temperature.  We can internally cool the station by moving the heat away from the sources using liquid ammonia running through heat transfer pipes, such as on the ISS.  The pipes allow us to take advantage of the convection heat transfer process.

Everything with a temperature more than absolute zero will radiate heat.  Radiation is the only way to remove heat from the factory, period.  We can transfer heat from one element into another or use a ‘heat battery,’ but in the end, it must come from radiation.  

A representative of Advanced cooling technologies put it succinctly, Think about a desktop computer with no fans.

Ammonia-filled Aluminum pipes that transfer heat into external heat radiators, such as those used on the ISS.  Another solution used in space often is water copper heat pipes. There is a new technology for heat dissipation in space using oscillating heat pipes (OHP).  These rotate depending on if they are facing the sun or not.  They are circular with radiator balls that rotate to maximize the heat transfer depending on their temperature.  They are being developed to cool current Nuclear engine technology for space travel.  It might be possible to disperse heat from the smelter with this technology.

Cooling the furnace is another beast entirely.  Standard methods will not provide enough cooling for a large-scale furnace.  Another more practical solution is needed.  Perhaps turning the newly smelted metal 180 degrees and pointing it away from the sun could provide additional cooling.  For the furnace.  We might need a liquid metal phase change heat pipe.

Poking holes: There might be a heat dispersion technique that we can use to cool the factory by creating an inverse piping radiator element with extra surface area.

No Sweat:  You can’t perspire in space, but perhaps there is a way to make the exterior push heat out in a different way.

On the ISS, thermal panels radiate heat as infrared light.

Wax cooling and water/ice cooling phase change material.

Project class: ES 

– – – – – – – – – – – – – – – – – – – 

Processing:

Shredder:  The module for breaking down materials into smaller pieces for easier processing.  It is the first step in the smelting process.  It crushes things down to a smaller size for future smelting or disposal.  It is designed to shred recyclables into small 10mm pieces.  The smaller size provides more surface area for the furnace and allows for easier identification, sorting, and purity scanning.  Shredders often adopt a semi-corkscrew layout to the knobby elements to propel materials through the machine.  This design works in microgravity.  Other designs might need a presser plate to push things through the process.  If the module were pressurized in a nitrogen environment, we could provide wind thrust to move fine dust through the shredder.  Think about a blender, one of the high-end self-cleaning types, except Industrial, and with the ability to shred steel.   There is a good chance we would need separate shredders for plastic and aluminum.

There is no such thing as a frictionless shredder.  However, some of the inner gear workings could operate with zero maintenance by using superconducting frictionless magnetic gears created by Radfield.  These gears require no lubricant and do not wear down.  They have been tested in marine engine systems.  

project class: ES 

Fine Grinder: 
Designed to powder materials into a final product for use in the metal 3D printer. Just as on Earth as is done with plastic and aluminum. The process also works fine for soft metals like gold, silver, copper, tin, etc.  We could add a heating element to facilitate molton metals’ natural reaction in microgravity.  When you turn solids into liquids in microgravity, the solids naturally take on a spherical shape.  The Find grinder doesn’t have to be massive.  Think peppermill. 

There is a process for grinding dark aluminum powder by filling a container with coarse powder and marbles or steel ball bearings and milling it for several days. This process can be done in space without fear of Oxidation (which causes an explosion). Perhaps we could get similar results from an automated, made-for-space, mortar and pestle apparatus. With Oxygen, this process could be used to make ALICE (aluminum oxide fuel) without many extra components.

project class: ES 

Furnace module: 

Manufacturing Component Kerbal:

Kmass: 59t You are looking at twelve convertotron kerbal processing units mounted on girders, in between 2 Airplane fuselages.  There are several fuel lines and support beams exposed internally.  The exterior is covered in heat radiators.   There are additional radiators that extend straight down.

My friend Jay Queenin suggested removing this module.  The project can work without it.  Taking out this module, or making it small, vastly reduces the difficulty and expense of building this station.   We are including it because of the manufacturing and recycling advantages.  Also, the refinery module cannot work without it. No furnace, no fuel.

The furnace can heat without the aid of oxygen. The process is called pyrolysis (thermal degradation).  The furnace also functions as a crucible allowing metals to be combined into alloys and allowing for additives such as flux (to add heat), zinc, copper, tin, etc. The smelter can be used to create alloy blends using powder recycled from different sources.  

It could function like a solar furnace using mirrors.  It could be a more traditional electric arc furnace (EAF).  There is something called a focused beam furnace currently being developed by compass technologies.  Perhaps they are working on a space-friendly electron beam furnace.  

The Crucible needs to be able to resist temperatures higher than the highest material being melted.  It doesn’t leave many options for material choice.  Thankfully, some ceramics can resist heat upward of 4000c for extended periods of time daily.  Traditional blast furnaces use slanted carbon bricks to expand and weigh 76 pounds each.  These Bricks have to be replaced every four years.

A maximum temperature of 4000c will allow us to melt anything in existence.  A maximum temperature of 2000c will still allow for water extraction from chondrite (rocky) asteroids and incineration of organics for fuel, and the ability to work on most metals.  

The melting point of various materials (with an Earth oxygen atmosphere):  These numbers could potentially change after providing more surface area by shredding the materials first while factoring in the microgravity component, which should provide less clumping and more surface area.

Platinum – 1768c
Gold – 1064c
Copper – 1084c
Aluminum – 1221c
Carbon Steel – 1510c
Stainless Steel – 1425-1540
Titanium – 1668c
Graphite – 3600c
Carbon Fiber – 3652 – 3697c
Mylar – 250c

This would have massive heat dispersion systems.  It is the main problem with adding a furnace module of any size.    There are radiators that project the heat into space. The ISS uses a sort of ammonia piping to transmit the heat into radiators.  Unfortunately, this would not be enough for a full-sized furnace.  

Heat pumps for heating the furnaces are much better than just electric heating, for obvious cooling load reasons.  I suggest that the cold side could be as warm as 300k (about 27c, a medium warm day 80f.)  Therefore, carbon dioxide might be your favorite coolant as it can operate all the way up to your hot side requirements with one coolant. (liquid on the cold side, gas on the hot side, pressures of 100 bar high side, and 10 bar low side, multi-stage for the hottest part.

Smelting in an environment without an atmosphere has a significant advantage.  We can achieve a higher purity due to the lack of oxidation. This high-purity recycled metal will cause the manufacturing process to be cheaper, easier, and, most importantly, better quality.  This allows for the creation of higher-quality materials.  

Concerns: how to design and include a form of the skimmer to help keep the purity up for melts?  

Whatever smelting process is used, there will be a waste product.  Thankfully, provided there is nothing too toxic in the slag, it can be safely disposed of in large volumes by burning it up over the Indian ocean.

Since the first version of this document, four thermal recycling designs have been proposed.  The first is by Northrop Grumman and uses a large parabolic reflector 50-100 feet in diameter and a spherical crucible for melting.  I am not positive, but I Imagine that it functions similarly to the Odeillo solar furnace in France, which can go from 0C to 3500C (6330F) in seconds. There is another similar project for mining water from asteroids using concentrated solar power optical mining from Trans Astra.

The second is proposed by Koch industries which sports a new type of Nuclear Reactor.  I am unsure what the rest of the process is, but I imagine incineration for gas harvesting.  I am sure someday I will get to read it.  

There is a third study focusing on Ablative Arc Electrolysis sponsored by NASA  (Ablative Arc mining for In-Situ resource utilization)  from Amelia Grieg, University of Al Paso, Texas. -2021 Nasa Grant for research 

OSCAR: The Orbital Syngas/Commodity Augmentation Reactor (OSCAR). This active project focuses on Organic Material but is supposedly capable of recycling other materials as well.  It is a rack mount system on the ISS.  For the time being, it takes carbon-based waste only.  OSCAR  uses heat, stream, and Oxygen in a furnace to  generate  “Syngas.”  It is a mixture of Hydrogen, Methane, and Carbon Dioxide.    The project will complete testing in September 2021.  One disadvantage is that it uses water and Oxygen to operate.   Oxygen and water that has to be shipped to the station from the ground.  It could potentially result in a net loss.  We will see when we see the numbers.  They claim that a crew of 4 produces 2,600 kg of waste per year.  But I am not sure how much of that is usable with OSCAR.  Trash to Gas (TTG) amazing stuff.   It has a max temp of 660ºC, which is hot enough to melt aluminum. 

Freezer: It also might be useful to have an industrial freezer.  It could help make some metals brittle and easier to shred.  It could also help turn gas into liquids for fuel purposes.  However, even a freezer creates heat.

project class: EEC 

– – – – – – – – – – – – – – – – – – – 

MANUFACTURING:

The project’s unique requirement of complex disassembly has the excellent perk of potentially being able to assemble equally complex things.  The Key to assembly is the Robotic Work bay.  The larger the robotics bay, the larger the thing we can disassemble or manufacture.  We believe robotic space assembly is the most important aspect of the project.  We have gone over the robotics bay in detail, so let us move on to the additive manufacturing process.

Several industrial experiments have been conducted on Skylab, Mir, and the ISS.  More recently, Varda, founded in 2020, is building a factory for space-made specialized semiconductors. They have  partnered with Space X and aim to launch a tester spacecraft in 2023 to manufacture things in space. Another project is to manufacture an existing drug into an injectable, which will take effect quicker.   They might make Zblan fiber optics in the future.  Varda factories are designed for specific tasks and are fully automated.  They feature a keyhole-type return capsule for up to 100kg.  It will be temporary and small.  However, they will likely succeed in building the first space factory. –https://varda.com/

After the materials have been ground into dust, smelted, and recombined to make alloys and printer-friendly composites, and ground into dust again for storage, we are left with optimum powdered feedstock for the additive manufacturing process.

Additive manufacturing is the industrial process of making things with 3-d printers.  Recycling with additive manufacturing would create a versatile, adaptable, and renewable industrial space powerhouse.  This analogy might not work, but let us give it a go.  A few hundred years ago, a fellow in the Netherlands named Cornelis Corneliszoon van Uitgeest created the wind-powered sawmill.  This innovation allowed the Dutch to produce many more boats than England and France and allowed for the birth of the Dutch East India Trading Company

3D printing:

Additive manufacturing is one of the cornerstones of the project.  There must be at least one printer for metal and another for plastic.  There would likely be several specialized 3d printers for various materials, sizes, and tasks. The printers, along with their assembly robot teammates, can make extremely customized parts such as expandable girder cartridges, circuit boards, electrical components, small fuel tanks, bolts, nuts, structural braces, cables, and wires. It allows for a great deal of adaptability for future missions, salvage, and repair.   

Some 3D printers, such as those used by relativity space to print their 3D orbital space rockets, can mix and use alloys.  Some alloys, such as common bronze, which is copper and tin, could be produced easily and used with said printers. It could prove to be a major advantage when manufacturing project-specific components.   

A presser.  Frequently powders are compressed and sintered to create high-density alloys.  It is often done using pressure.

The  Advantages of Oxygenless Sintering:  The main problem with off-the-shelf modern metal 3D printers and filaments is that they oxidize during the final process.  This makes the metal more brittle and also reduces the shine and whatever other metallic characteristics of the final product.   Operating in a vacuum has some serious advantages in terms of material quality.

3D printers require a separate furnace.  It is needed to melt the feedstock into a liquid.

 This would likely be a much smaller electric furnace than a more industrial large-scale furnace.  It has been done before on a few occasions, but it is important to understand that heat factors in space make things a bit more complicated when dealing with high-heat units. 

NASA has fully committed to building a system for production in space called Fablab. The plan is to test an integrated multi-material, on-demand system by 2020.  It is 2022, and it is not complete.  But I digress, and they have progressed in leaps and strides.  It is designed to be able to print almost anything, including human organs.  Fablab comprises rackmount modules built by several companies,  including Redwire, Interlog, and Tethers Unlimited.  All these modules fit within NASA’s EXPRESS Rack system, which provides 28+1.5/-2.5 Vdc up to 20A for each locker location (max 500 Watts at any location). https://www.nasa.gov/nextstep/fablab

How To Make A Bong in Space:  3D printing has progressed in leaps and bounds in the past ten years.  Metal 3D printers on the market can use composite alloy filaments without creating a ceramic mold.  3D printers are a quiet revolution. I work in a headshop.  Between the 3 of us, I have the only college degree.  I have a degree in art and postmodern philosophy.  No engineers, no scientists.  However, my co-worker Chris is a blackfoot (term for a mechanic in Mad Max).  We have started printing custom bongs, grinders, keychains that say las vegas, lighter holders with your name on them, etc.  We also use it for custom bicycle parts such as form-fitting battery containers and light and electronics housings.  (my friend Chris makes batteries).  For the Bong, we use a glass piece for the bowl. The rest is plastic.  If we can do it in a headshop, we can do it in space.

3D printers:

Relativity Space:  prints Rocket Thrusters on Earth with a turnaround of about 12 hours.  They have been working on how to 3D Print a rocket on Mars. Their factory has the aforementioned ability to mix different alloys custom for every print job.   They are the current favorite for development of this element of the project.  Very cool stuff.  

Project Class: ES

The Polyformer is a machine designed to turn plastic bottles into 3d printer filament. It cuts and heats the plastic bottle and extrudes it into FDM filament.  Its creators Reiten Cheng and Swaleh Owais have taken a real altruistic approach. The machine’s design blueprints, cad drawings, source code, and building instructions are available for free online via the team’s discord.  –good news network

The Polyformer is not necessarily compatible with the multi-functional powder-based system we are proposing.  There isn’t much low-quality plastic in space.  We are not sold on the extrusion method. However, it is, in concept, exactly what we are looking for.

Project Class: NEN

Refabricator: is a plastic 3D printer and waste plastic recycler combination device built by tethers unlimited. It was launched to the ISS in 2018. There are plans for Refabricator to work with metals as well.

Project class: NEN 

Trussleator: It is built by Tethers Unlimited to print trusses for large structures out in space. 

Project class: NEN 

Link: http://www.tethers.com/

Lumivec by Interlog, Is the second project selected for FabLab. It features MMAMT (Multiple Material Additive Manufacturing Technology). This is capable of 3D printing using several different materials. 

Project class: NEN
Link: http://interlogcorp.com/new-technology/

The AMF (Additive Manufacturing Facility) from Redwire is built for plastic recycling. This is one element of NASA’s FabLab already in use on the ISS.  It was launched in early November 2019.  It is an amazing breakthrough technology. However, it uses a specific plastic. “GreenTM polyethylene”  We need something a bit larger and more robust.

Project class: NEN

Link: https://madeinspace.us/capabilities-and-technology/plastic-recycler/

Autodesk 360 with Haas (as seen on battle bots)  for making custom parts on the fly. Adaptable, battle-tested, efficient, and quick. It will print plastic and metal parts and works with widely known existing software like Autocad.

GE Aviation makes a decent metal printer.  It prints using selective laser sintering, which uses powdered aluminum. They are not made for space and would be heavy.  However, it might be adaptable.

Project Class: EEC

Link: https://www.ge.com/additive/additive-manufacturing/industries/aviation-aerospace

Esam, by Redwire, is a 3D printer that can print objects larger than itself.  It is rated for space and can use a wide variety of feedstock. Their videos involve printing trusses in space.

Made in Space (Redwire)  also made and tested a fiber optic cable manufacturing module.  It prints Zblan, which is several times more effective than normal Silica fiber optic cable but requires a microgravity environment for production.

Project Class: NEN

Link: https://madeinspace.us/capabilities-and-technology/fiber-optics/

Archinaut-1 by Made In Space (now Redwire) focuses on additive manufacturing and robotic assembly technology.  It has been tested by NASA. Archinaut can print large objects in space, such as 40-meter antennas, truss rods, or solar panels.  It doesn’t fold out like the James Webb space telescope.  It 3D prints components on the fly in a zero-gravity vacuum. Archinaut-1 is a stand-alone craft.  It is scheduled to launch no earlier than 2022.

Project Class: NEN

Link: https://madeinspace.us/capabilities-and-technology/archinaut/.

The third project for NASA’s FabLab is not relevant to this project but let us mention it anyway. It is cool.  Techshot built a 3d printer in space for human organs.
https://techshot.com/

Project Class: NEN

There are also robots that 3d print the Delta 4 carbon-fiber fuel tank.

Project Class: EEC

(update: August 2019) Lockheed Martin has been awarded a federal government contract to develop an aluminum powder 3D printer for use in space.  It does not have a name yet. There are no links.  They got this contract after I submitted my proposal 😉

None of these printers, except perhaps Lockheed’s design, will do the job well.  Fablab is a great start!  However, its need for use in a human-friendly environment and limited use for recycling makes it inadequate for the task at hand.  Redwire is working on some amazing ideas. Relativity Space is the best candidate.   None of them can print on a large enough scale.  None of them can process steel.  There are likely things we would have to engineer from scratch.

Standard Production:

 We might also be able to build a multi-material injection molder with some sort of memory gel, perhaps a rough-casting sand mold where the sand can be reused to make future molds specific sizes and shapes.  This would also require an additional furnace/heating unit.  When Skylab was launched into space, there were no 3D printers.  They were experimenting with more standard bending and shearing equipment.

An industrial cutting module might not be bad for cutting full metal sheets or the like out of manufactured materials.  

Finishing module:  Sandpaper and sanding equipment can grind down stray artifacts and make a massive difference in the end product. There are several other techniques for putting the finishing touches on a piece.  A dedicated finishing station can be built. A sander could also help with removing paint. 

Project class: ES 

Standardization in manufacturing:  This is particularly important for restoration.  The goal is to make a compendium of easily interchangeable parts.  We would like to be able to manufacture parts that could potentially be used with spacecraft and satellites internationally.  The secondary goal is to create standardized sizes and pallets for the new stellar craft.  This could perhaps be a set of 3 standard sizes.  Small (CubeSat-sized),  medium (uncrewed Interstellar observation craft), and large (station module).

Standardization could also be integrated into the salvaging process.  We can create standardized orbits by moving as much space junk as possible into a counterclockwise low Earth equatorial orbit, allowing the pickups to happen effectively in two-dimensional space.

Standardized Manufacturing:  
Modular Design Elements: 
Standardized components:

Artificial intelligence for repetitive tasks  AI has the ability to speed up the process using AI-Assisted intelligent manufacturing.  Not every decision has to be made by humans.  It might be possible to use primitive artificial intelligence to help out with some of the design and engineering work.  We will have readily available templates saved in the massive space parts database from previous research and construction. The templates might be easily modified with less human intervention.

Recycling:

Aluminum and Polymer (Plastic) are the cornerstone of our manufacturing process.   Aluminum and high quality plastics can be recycled using a strictly mechanical process involving shredding.  

Exact materials commonly used in space to be recycled: 

Stainless Steel 301 
Stainless Steel 310s 
Aluminum Alloy 2219 
More…

Aluminum Recycling:  Aluminum is the most plentiful and most easily processed material in low Earth orbit. The system is designed for this.  Aluminum develops a surface coating of oxide, no matter how pure, unless not exposed to an oxygen atmosphere.  It could necessitate the need for a furnace. 

project class: ES 

Plastic Recycling:  Heating and Extrusion machine for HDPT (High-Density Polyethylene)  plastic to create filament for a 3D printer. The Refrabricrator experiment on the ISS processed plastic feedstock over and over to see how often it can be reused before its polymers degenerate and become useless.
project class: ES  

Carbon fiber recycling:  Our system would allow for a recycling process using heat and milling to make a graphite-like substance.  However, it might not be possible to 3-D print into parts. Alternatively, it can be incinerated and made into gasses. This is the recommended most cost-effective solution terra side. Carbon fiber Incinerates at 1000C. You end up with a char (about 75%) consisting of about 91% carbon. However, the process can also generate a significant amount of Hydrogen2 (around 8-10% wt) and a significant amount of Methane (5% wt)(CH4).  It is outlined in a 2018 Study done at The Chemical and Environmental Engineering Dept in Bilbao, Spain, and the National Center for Metallurgical Research 

project class: ES 

Recycling Titanium:  It might be possible to make memory metals or other strange composites.  Titanium could be tricky to recycle because of the high temperature required compared to Aluminum.  It would be worth it if we could.  There is plenty of Titanium in space.  

Project class: ES 

Recycling, Restoring, and Manufacturing Batteries:  (to be edited)

Lithium-Ion
Primary Lithium (non Rechargeable) 
Alkaline:  not be many of these in space
NIMH (Nickel Metal Hydride)
NICAD (Nickel Cadmium)
Silver Oxide (SI-OX)
Lead Acid Batteries (Car Batteries)

Solids: Lithium, Mercury, Zinc Manganese Concentrate, Copper, Nickel, Cobalt, Cadmium, Steel, aluminum, graphite, paper, plastic

Liquids: Potassium Hydroxide

project class: NEN 

Project Class: ES

Recycling and Refurbishing Solar Panels: Solar panels contain a large amount of glass, around 80%.  Most PV cells also have a large amount of Silicon.  

Project class: ES 

Recycling PCB (Printed Circuit boards): 

project class: ES 

Recycling Nitro Cellulose: Used in rocket fuel, records, nail polish, paints, lacquers, guitar picks, film, explosives.

Recycling Polyurethane: Recycling polyurethane would be very similar to plastic, except that it might not grind down into usable feedstock without chemical changes.  It can still be refined back into methane, oxygen, carbon, etc.

Recycling Industrial Chemicals:  A closed-loop for recycling specific chemicals.  It allows us to reuse said chemicals over and over.  The process would also be used for cleaning chemicals. 

Alternative Recycling:  Kapton (heat insulation material), Quartz (for communications), Carbon fiber, fiberglass, and other glasses, graphite, kevlar, mylar, styrofoam, and organics. It can all be ground down into dust for processing and manufacture. It can all be converted to gas and separated.  Some things require a chemical process to recycle, which will not be cost-effective based on launch costs unless the smelter can be multi-purposed for other types of recycling. Materials that cannot be used in their current form will be ejected and burned up in the atmosphere. Some components might be too difficult to melt down and process. It might have to be saved for future projects. 

Project class: ES 

Waste to Fuel: It might be possible to make liquid aluminum fuel from recycled materials (ALICE). There might be other gasses that can be captured depending on what gets melted.   We could also produce Silane, similar to Methane but with a silicon atom instead.  Like ALICE, it can also be used with an oxidizer as rocket fuel.  There are a few issues though.  Very few things in space break down into oxygen.  Whichever fuel we make, it will still need an Oxidizer from the ground.  Also, The only fuels that are cost-effective for the project are noble gasses.  Not much, if anything in space, breaks down into noble gasses.

Project class: ES 

Refinery:

If we are going to build the furnace, it makes sense to build a refinery.   It allows us to capture gas as a product.  Gasses in space can provide power or propulsion.  They have additional uses, such as using C02 for cleaning the station.  Because of the lack of oxygen, the auto-pyrolytic effect of the furnace allows for the station to Capture gasses from the thermal recycling process. The refinery sorts extracted gasses and compresses them as needed for storage. There would be some form of electrolysis to split gasses and a reboiler thermal element for a similar effect. A pressurizer would be a third option. Filters for particular elements such as Hydrogen, Methane, Nitrogen, and Carbon Dioxide, and at some point, converting as much as can be converted into Oxygen and carbon Monoxide for fuel. Unfortunately, there might not be much oxygen gained from the process. 

This Module allows the project to make fuel from the incineration of organics. (Plastic, Carbon fiber, etc.)  We might be able to produce ALICE (experimental aluminum oxide propellant) in-house.  There is another variant of Alice that uses Iron powder instead of aluminum.  

There is another fuel option.  It is Sih4. The silicon hydrogen-based fuel is known as silane.  It is an option being researched for lunar outposts with the same lack of carbon material issue.

Project Class: ES. 

Growing Fuel: Getting enough oxygen to power the salvage fleet is a big problem.  There are no humans.  No one needs to eat.  But a hydroponic algae greenhouse might be able to solve our fuel problem.  It might be possible to convert Co2 from Industrial processes into Oxygen for a standard LOX and ethanol-based fuel combination.  Oxygen is important for most rocket fuels except noble gases for Ion Thrusters and monopropellants for RCS thrusters.  ALICE was mentioned before.  The Oxygen can be combined with powdered aluminum and frozen to create ALICE, an experimental rocket propellant, or for use with hypergolics.  It is not a great solution, but it would enable refueling for missions inside low Earth orbit.

project class: ES 

Converting Fuel: It is possible to break down hydrazine.  It is hypergolic and must be mixed with oxides of nitrogen to combust.  Otherwise, it is more stable than most fuels.  Hydrazine can be separated easily by passing over a catalyst metal.  However, modern rockets vent excess propellant for safety purposes and to prevent boosters from exploding.  Most Satellites are declared dead when they run out of propellant, so there might not be much to convert.
Project class: ES 

Gas Compression and Cooling: Methane and Hydrogen will need to be cooled and compressed to be stored.  Starship runs on liquid methane and liquid Oxygen.  We can produce liquid methane and might have the ability to do limited runs of Oxygen.  

 Project Class: ES.

Gas Station:

The Aforementioned OrbitFab already exists.  However it focuses on Hypergolics for SpaceX’s raptor engines.  Optimally, we would need an integrated fuel depot which focuses on Noble gasses.  Alternatively, we can provide powdered aluminum and perhaps a refinery for aluminum oxide or mixed as fuel (ALICE).  However, for ALICE, we need Oxygen.  We can also incinerate carbon fiber and plastic to create Hydrogen and Methane.

Project Class: EEC

Precious Metals Separation Storage and Re-Use: 

Gold Separation is a chemical process.  There are several ways to do it, but most are very expensive. The chemicals would have to be replaced frequently and likely outweigh the metals in question.  If a closed-loop chemical cleaning solution were possible, we could do significantly more in the way of recycling. One terrestrial way is where nitric acid separates gold from aluminum, ceramic, and desolder leads.  Another way uses borax, hydrochloric acid, and bleach.  However, with the cost of sending large amounts of chemicals to the station and the value of materials in space, the chances of making a profit are slim.  Some gold plating can be separated by mechanical means, using the space equivalent of sandpaper.  There is at least 2 oz of gold per satellite.  There are 6500 defective satellites.  They weigh in at 13000 oz of gold currently on the terrestrial market at $1200. Shipping it back to Earth could profit $15,600,000.  The result is that the gold is worth more in orbit.

Project class: ES 

Advanced Materials to be created: 

The Wake Shield Facility (WSF-3) built by Space Industries Inc (now part of General Dynamics) was deployed from the space shuttle successfully in 1996.  Its purpose was to make semiconductors and thin pieces of film.  The crystalline semiconductors were 10,000 times better than the ones made back on Earth.

Zblan needs to be stretched out like a fishing line which requires microgravity.  Redwire’s ISS organics printer, which prints organs, also requires microgravity as the organs come out like mush if we print them on Earth.  Metallic liquids, all liquids, in fact, become perfect spheres if they cool back into a solid form.  Perhaps there is something worth learning about in the development of microgravity nanocomposites.

 A diamond anvil is what it sounds like.  It squeezes atoms between a pair of diamonds for high-pressure research.   It was used to prove the possibility of liquid hydrogen  (a potential rocket super fuel).  It is like a presser for atoms.  It is the sort of thing that might be useful for advanced materials research, study, and even production.  There is a stability issue for production depending on the atoms in question.  Perhaps these stability factors are different in a vacuum where there is nothing to bond with.  

New research suggests that production in space enhances the ability to manufacture smart materials with the ability to self-assemble in microscopic structures. 

Project class: ES 

What can we manufacture?:  

Phase 1: (no furnace) We can manufacture retrieval craft(JunkBots), truss works, storage containers, fuel tanks, cables, wires, heatsinks, piping, circuits, structural elements, and other easy parts for the station.  

Phase 2 (with furnace and refinery): propellent, sheet metal, satellites, space telescopes, spacecraft, habitats,

Large Scale Manufacturing (optional): 

This proposal is not focused on manufacturing as much as materials acquisition and processing into a reusable form.  However, some amazing proposals are out there for what to do with the materials,. There is Archinaut Ulysses by Redwire or the GSal by Orbital Assembly Tethers Unlimited Spiderfab system, and several others.  Our stationʼs plans include 3D printers for both plastics and metals, but the scale of those projects and the size and weight of those printers might be limited.

Project class: ES

Compactor:  In some instances, we might manufacture raw materials with a low particle density.  A simple module for saving space by compacting raw material, especially waste material, might be useful.  

– – – – – – – – – – – – – – – – – – – 

Structural Support Truss: 

If the station is launched into an equatorial orbit.  We would take the truss from the decommissioned ISS.  It is an engineering masterpiece that took several space shuttle launches to build.  It is sturdy and long.  It would be perfect.  

Things might be more difficult for the polar orbit version of the station.  We can assemble the truss in the robotics bay, but we would still have to ship it up in parts.

A few companies are working on expandable truss systems that could be launched from the ground.  Redwire Space won NASA’s contract for OSAM-2 Archinaut.  These innovations could be a solution for a truss that could work for solar panels, science/radio towers, or extensions for robotic arms.  However, an expandable truss might not have the same structural integrity.  It might be too weak to sustain the physical stress generated by the station’s vibrations and high-volume docking.  We also might not be able to attach other modules to it.  Perhaps we could build some expandable truss modified with hard supports in the robotics bay.

If the robotics bay is shipped up in Starship, it makes sense to ship up the Truss in starship too.  It would likely be an exact fit.  It can be included in the first launch.  We could even make double-sided payload bay doors so the truss can easily descend from the bay and then lock into place.  The truss contains oversized reaction wheels, batteries, connection ports, and retractable solar panels on the nayward side.  It almost feels like cheating.

Kmass:

Project class: ES

Generic Station Hub and connector: 

This basic 6 Sided Craft has a docking port on each side.  These are “deluxe” multi-directional docking ports.  They are large and made for structural integrity, factory work, and to enable future design changes and expansion.  This module would also help facilitate module-to-module materials transportation. This component is self-contained.  It will have the ability to move to some extent.  It has massive reaction wheels, at least as big and maybe significantly larger than the CMGs (control moment gyros) used on the ISS. These are used to help the station stabilize and perform rotations.  The module has remote guidance and communications.  The module also includes large batteries and RCS thrusters.  These thrusters allow the module to make short-distance moves and reposition itself around the station.  The module would also be capable of being moved via a robotic arm.  Building a space station isn’t easy.  The simpler and more standardized we can produce things, the better.

Generic Station Hub and Connector Kerbal: 

Kmass:  9.636t This module evolved after several attempts to make space stations that did not go as planned.  This piece allowed me to make a stable platform on which to build on.  It features two massive reaction wheels, a large battery, a large command and control element, six large docking ports, and eight five-way RCS thrusters.

Project class: ES

Reaction Wheels and station orientation:

The way reaction wheels work is that they can only spin so much before they reach saturation.

“Reaction/momentum wheels are flywheels used to provide attitude control authority and stability on spacecraft. By adding or removing energy from the flywheel, torque is applied to a single axis of the spacecraft, causing it to react by rotating.” -Nasa.gov

When the reaction wheels reach maximum torque, they become saturated and stop working.  On the Iss, if the reaction wheels become saturated, they need to use monopropellant cold thrusters to desaturate the wheels.  The smaller the reaction wheel, the less torque it can apply, and the easier it becomes saturated.

For this reason, A station of this size needs massive reaction wheels.  They partly compensate for the station’s large mass and stabilize its external moving parts.  The ISS uses several heavy gyros more than 2 meters in diameter.  If we were to build that robotics bay out of a salvaged Saturn 5 rocket booster with a ten-meter diameter, it stands to reason that the station would need at least a five-meter diameter reaction wheel.  The bigger, the better.  It would be phenomenally heavy.  Perhaps 20 tons worth of reaction wheels mounted on the truss.

The alternate solution used in one of the kerbal RSVs (RSV1.4).  Several small reaction wheels are supported by trusses extending a few meters out from the ship’s center of mass.  on smaller truss beams in symmetric directions.  It makes for a very stable platform but presents problems during the extensive docking and rendezvous procedures necessary for normal station operation.

As the Station fills up with materials and salvage, it will get heavier. The weight will create a natural ballast.  It is a good thing.  It means the station will absorb more kinetic energy when external elements move.  However, it will make changes in position more difficult, slower, and more energy costly.

Shakin all over: Some of the modules are industrial factory components. They will have more vibration or shake than standard ISS modules.    In Kerbal space program, there is a mythical beast called The Kraken, who comes in and makes sure your ship suffers from rapid unscheduled disassembly to any spacefarer brave or foolish to attempt non-standard configurations.  There are tricks like adding excessive steel struts to absolutely everything, but the Kraken is rather unforgiving.

For this reason, reaction wheels are extra important.   The station’s actual mass is also important.  The heavier it is, the less it will shake.  There will have to be some innovative vibration-dampening solutions or at least scaled-up and creatively applied existing solutions.  The most important thing is structural integrity.  There will be no way to stop the shaking completely.

One of the main vibration issues is the shredder.  It will need some form of vibration dampening. This shake of this module will likely cause a problem called procession.  Procession is where the craft spins end to end uncontrollably.

You never know when a component might not act exactly as anticipated. Therefore, everything must be built with maximum structural integrity in mind.

Station stability is required for safe docking procedures.

Project class: EEC

Armor:  

Kerbal storage Module:

Kmass: 400+ tons The Idea from kerbal is to put the docking ports on top of the cargo containers, using the containers to protect the rest of the station in case of a mishap.

Armor and station construction.  Another lesson learned from the kerbal salvage operation has to do with the day-to-day safe practices of operating a high-traffic station.   The first few designs were built like a boat with areas that look or function like conning towers or sails.  It turns out that all of those designs were flawed.  The first lesson was to reverse everything.

The most recent designs mount the docking ports on the top of the cargo containers.  With the cargo containers oriented top relative to the station as well.  Those cargo containers, as well as the robotics bay, protect the factory elements, the truss, power, and communications on the off chance of a manned component; The armor would protect the meatbags from mishap and space debris as well.

Storing Aluminum, Steel, and plastic as thin metal strips in bundles or spools inside the storage containers on the nadir side of the station where all the berthing and docking is.  The idea is to create bundles that bend rather than break to provide more armor for the station in case of collision or other mishaps.  Another good reason is to prevent feedstock powder from dispersing into space.   These strips can easily grind down into powder feedstock when necessary.  It is counter-intuitive to the pod storage system, but it would make effective armor.

The shuttle-type repair bay doors are flat instead of curved and steeply angled like a roof in a northern hemisphere house or Zumwalt class destroyer.  The angle of the doors is optimized to minimize damage from impact.

The repair bay and the doors can provide a basic level of protection.  The bay is positioned at the proverbial, not Earth-facing, top.  Below being Earth facing, Top being space facing.  The repair bay and storage modules protect the critical components below it, such as solar panels, reaction wheels, command and control, communications, and industrial modules.  Sometimes the orientation needs to be changed for docking needs or brace for an impact with debris.  This allows the station to orient itself to prevent debris or docking mishaps from hitting the delicate bits.  Sure, there are odd orbits of untrackable space debris that can cause a collision from below, but this design reduces those chances as much as possible.   It might be a bad analogy. The docking ports also face upward for the same reasons.

The I.S.S. uses a Whipple shield, which uses the inherent velocity of the debris to slow it down.  The debris explodes, breaks apart on the first layer, and has substantially less force when it hits the second layer.  It uses several thin layers of thin aluminum and kevlar and works for small objects up to 4cm.  This sort of Armor could potentially be made using layers of steel and aluminum sheets repurposed from rocket boosters. Alternatively, aerogel plating could be added in between plates instead of kevlar.  The result would be much like the pastry Baklava.

The Hibernia GBS Off-Shore oil rig coated the base with ice to prevent Icebergs from destroying the rig.  Perhaps we can use something to create a similar effect.  Another thought about how to armor and what to armor with concerns storage.  If we can process steel into sheets, we can store it on the outside of the gas tanks, other pressurized modules (if any), and sensitive components. This is likely the best solution. Steel and Aluminum from rocket boosters launched in the ’60s and ’70s could be repurposed. Perhaps we can use slag processed into a tar paste which, on cooling, solidifies.

There might be another option. It is more directly related to the iceberg protection idea mentioned earlier.  Methane freezes at  -181C.  The vacuum of space varies based on the sunlight but is typically -270C. Frozen methane armor and fuel storage might be possible.  Perhaps some system that uses layers of fabric with cooling pipes sewn in to solidify Methane when needed.

Project Class: ES

Self Repair:  The station can replace used-up or damaged components with parts made on-station. The deluxe version would be aided by the help of artificial intelligence. There is currently a NASA Solicitation for self-repairing fuel tanks, such as those used by the United States Army on their M series troop carriers.  It is a chemical process that might be hard to re-create in space, but it would be useful for storage, especially pressurized storage. 

project class: ES

Station Cleaning:

The station has to be able to completely clean itself. Unfortunately, since this is a factory, power plant, recycling plant, space mechanics shop, and depot, there will be many things to clean. Perhaps shutting down the station entirely and establishing a program for self-cleaning mode would be the best way of doing things. It probably won’t use water. Perhaps another substance is more suited to the task. It is best to avoid cleaning chemical and liquid resupply launches as much as possible. A thorough Station cleaning would likely require launching rockets full of nitric acid, distilled water, and other chemicals for recycling, etc.  It would be good if this could be reduced to once a year or longer.  We can at least send back expended liquids and waste materials reliably and safely using the same cargo module.

The WRS (International Space station Water recovery system) would have to be modified to filter out nastier stuff like aluminum dust or worse. On the ISS, all solvents can be refined by distillation, so getting to clean water from dirty water is only heat, pressure, and cooling away.  However, it would not have to purify to the level of drinking water.

The station should have enough extra liquid Carbon dioxide, which at about ten atmospheres pressure and at ordinary human comfortable temperatures, is an excellent cleaning solvent and has a clean and easy recovery.  However, cleaning liquids only work in a pressurized environment.

A closed-loop system to recover liquid carbon dioxide as gas after the cleaning procedure would work best.  I recently had the privilege of using a professional carpet-cleaning device. It applies steam with one nozzle and reclaims the water with another sucking nozzle.

There would be less friction and no oxidation in a microgravity, unpressurized industrial environment.   This might help reduce ongoing maintenance.  

Project class: ES 

Muck resistance: 

Some industrial surfaces can be coated with “SLIPS,” Slippery liquid Infused Porous surfaces.  Joanna Aizenberg created these non-stick surfaces.  The Aquarius Bunch Wrapper 800 Micro Lollipop factory uses a special coating to prevent the machines from jamming up on sugar dust.  

Project class: ES 

Station Maintenance: 

ISS Maintenance Schedule and how it would relate to an unmanned system.

Maintenance of internal robotics components

Maintenance of internal factory components

Materials Cleaning Module: 

Perhaps a module filled with liquid for removing irregularities or other particles that could affect the purity of the final product. The module would probably employ liquid detergent biocide as well as air and water, which are recycled and reused. This is how it is done on the ISS. 

Project Class: ES 

Docking and materials transfer Ports:  

The International Space Station’s universal docking system could be incorporated for new modules.  It currently has the capacity to do liquid transfer for refueling.  The Robotics module will also have bay doors like the space shuttle for Berthing procedures.  There is another standard for docking with satellites for servicing by Lockheed.  It is the Standardized Satellite docking port from Lockheed (MAP). –Lockheed.  The pneumatic tubes might require their own connections.  Factory modules might need to be reinforced to the truss. 

Project Class: NEN. 

– – – – – – – – – – – – – – – – – – – 

Command and Control:

This would include navigation, command, control, etc.  A SIRU Space Inertial Reference Unit gyroscope.  Having a central terminal with a few backups might work. As well as several dummy terminals which control operations of components with little or no CPU involved, all computation is done from a central system. Or in case of emergency, done on the ground.   The idea is to keep things as simple as possible and on a component level to avoid system failures.  (edits needed)

project class: EEC  

Computers: We need several tons of computers to run the unmanned station.  Every robot needs a computer.  Every camera needs a good deal of data processing for object recognition. Every picture and the data generated needs to be stored.  Design blueprints need to be stored. Components data need to be stored.  Every pod in the pod storage also has data that needs to be stored.  Contents, status, and location are just a few.  Running an automated factory with any amount of adaptability involves massive amounts of data, processing, and storage.  

Locally storing the data provides a speed advantage as well as an amount of security.  There would likely be a limit to how much data we can store locally. Some data might need to be transferred back to Earth for long-term storage.  Some of the data beamed back to Earth and deleted would be Old camera footage and data from instruments and tools for completed projects.  

Artificial intelligence: 

Much has happened since this proposals conception many years ago.   What can be done with AI has changed in a rather dramatic way.  The A.I. can assist with decision-making for servicing and repairs.  This might come in the form of a recommendation for a pre-scripted program all the way to autonomous assembly. It will help with data management and tracking inventory..  Artificial Intelligence will also help run the station systems such as temperature, power management, and station upkeep.   There will be significant use of A.I. for object recognition in the sorting process.   For some tasks the will have the ability to assign priority for human review.  However, at the rate of artificial intelligence improvement, and the direction technology is taking, there is no reason why the whole station cannot be run with A.I.   

Project class: EEC

Software and Software Development:  

In addition to Computers, we might need as much as a Billion dollars worth of computer programming. Everything in the station would need some sort of programming.  Industrial components, The robot workers, the salvage craft, The identification systems, the A.I. components, including object recognition, sorting and inventory control, station command and control, communications, and so on.  At the very least, some code would need to be optimized for space and, more specifically, this space station.  Components need to be able to talk to each other and work together.  To do that, we need to build some sort of master framework, an API for the framework, and integration to all the components.  The more the station is automated, the more coding old be needed. 

Project class: ES 

Realtime Control Interfaces:

In 1965, Ralph Mosher built the walking truck while working for General Electric.  It was an inspiration for the AT-AT from Star Wars.  It was also an amazing machine.  It did not use computers and had a human driver with an interface that enabled the driver to walk the 3-ton truck over difficult terrain.  Its interface used hydraulics with an interface that used the controller’s arms and legs to create some natural feel for walking or pushing things with its legs.  It was made for the war in Vietnam.  It was meant to replace the jeep.  In the end, it wasn’t nearly as effective for combat use as a Huey helicopter.  Some of its design has been built into Boston Dynamics “spot” dog robot.  We have come a long way since the walking truck.  Creating a real-time tactile interface for a robotic human worker is not inconceivable.  It can be built with a raspberry pi and the proper sensors in the proper places located around the human body.  This project could have worked before Artificial Intelligence or even modern computers.  

 VR and virtual reality control interface. Perhaps some virtual reality custom interface, real pilot controls with a virtual interface. The pilot has a seat and whatever controls are needed, joysticks for robotic arms, etc. There are several options for a real-time tactile manual interface. 

The most simple interface could be two apple watches working in combination. There are many wearable smart devices these days.  Watches rings, necklaces, glasses, and even full-body suits.  There are limitless off-the-shelf options for tactile remote control interfaces https://owogame.com/.  

There are more advanced wearable projects, such as Mimu gloves made by Dr. Kelly Snook.  They use motion translated into midi to make music but could control robots too. 

There are even telepathic control devices, such as  EEG brainwave sensors which can be used to control RSGS or robotics workers in the service bay.(Neurosky). This technology was featured in the 80ʼs movie “Flight of the navigator.”    Everyone’s favorite billionaire Elon Musk is currently developing similar product called Neurolink.   

I was diagnosed with ADD (ADHD) when I was very little.   I was the kid with the aderol perscription. 30 years ago, when I was in high school, one of my former Hebrew school teachers reached out to me .   He was working on a very strange project.   The goal was to cure attention deficit disorder by training my brain.   The training involved an EEG connection to my temples and a computer screen.   The screen had various games. One such game was make the fish swim around the tank.  The only way to make the fish move was by thinking on the right frequency.

The military uses its own system for training.  The ATARS Airforce combat simulation, made by red-6, involves augmented reality to simulate combat scenarios.  It is “A video game in the sky” Similar technology could be employed in the unmanned robotics bay or salvage missions.

Project class: ES 

Sensors:

Cameras everywhere: The need is obvious for some areas, such as the robotics bay.  We need as many cameras as possible in order to be able to control robots from the ground for the assembly/disassembly tasks at hand.  We need as many eyes as we can monitoring the station. They can be standard high-resolution cameras.  Some of the other cameras in the factory will need to be highly specialized for the task at hand.  Some might also measure heat or light. Some might operate in the x-ray spectrum and the infrared and ultraviolet.  Several will be oriented to provide specific information for specific tasks.

There is “RAVEN” relative distance calculator and autopilot (uses lidar, infrared and visible spectrum sensors), Laser range (lidar) finding, plus 3d scanning and imaging for mission formulation.  It is used for RPO (Relative Proximity Operations), as demonstrated with the DARPA RSGS program.

Project class: NEN 

Communications Module: 

Starlink and other constellation communication satellite networks guarantee near real-time control from the ground for this low Earth orbit station.  All communications would be highly encrypted for safety and security, as well as to comply with regulations and prevent causing interference with other communications satellites.

Project class: NEN

Near Object Tracking: 

ERA 3D map for collision avoidance throughout the scrapyard with a real-time inventory system that tracks the movement of all materials through the station and all craft associated with the station. Double-mapped with infrared sensors and video cameras for a secondary dataset for further collision and accident avoidance. Lastly, elements of modules can be color-coded using small dots of paint for visual identification.  It is the system used on the ISS. 

project class: NEN 

Safety Harpoon: Emergency Harpoon launcher for failed berthing actions and other potential docking mishaps could also be a net or hook.  The projectile can be shot via an electromagnetic linear induction motor.  Whatever the projectile, it would be connected to a tether out into space, capturing the space junk and winching it back to the station.

Project class: ES 

Detonation charges: In the event of a total catastrophe, we might have to Scuttle the station.  Explosives would be strategically placed to break up the station to prevent the station from de-orbiting as a single object.  The pieces have a greater chance of completely burning up and minimize the risk to life back on Earth.

Project class: EEC

Death Thrusters: 

Small RCS thrusters should be installed on each module to ensure that as much of the station as possible enters into a semi-controlled burn into the atmosphere in the event of catastrophic failure. They would not rely on systems otherwise integrated into the rest of the station.   These thrusters would help insure that most if not all of the station and station bits that don’t burn up in the atmosphere are safely deposited in the Indian ocean at the right location, with minimum risk to human life.

Project class: EEC

Optional Subsystems:

Double-sided pod and slag launcher:  (Shipping and Trash disposal}

To launch things out into space with at least some velocity, we would use a (Mass driver) electromagnetic linear induction motor (railgun).  The ” railgun ” propels our standardized material transfer pods and other miscellaneous equipment to where it is needed, or de-orbit industrial waste and other trash.  It can send CubeSats to higher orbits. It would likely take the form of a round steel beam with a charge or electric application of force.  In order to maintain a stable orbit, it might be double-sided.  One side would shoot slag as ballast.  The ‘gun’ would have to be able to swivel along the x and y-axis.  Both sides of the launcher would be able to be configured independently.  Charge and direction would be separate but equal in order to maintain a stable orbit.

The launcher could be loosely based on the Titan launch dispenser, which the United States used to launch a few satellites simultaneously into different higher orbits. The Dispenser used Gasses for propulsion. Another option would be a whip-styled catapult, as suggested by Neal Stephenson in SevenEves.

Project Class: ES 

Alternate to slag cannon:

 A big ball of ash and residue from melted foam wood cloth ceramics, and anything else that melts could be stored as a ball in an inflatable balloon that increases in size over time. Perhaps it might be useful later.  Perhaps we can use it for armor.  We can put a booster on a big ball of trash and aim it at the sun if we want, an asteroid defense system, impact shields for a manned station, and get an entry into the Guinness book of world records for the largest manmade object in space. It would likely be radioactive. What do you do with a giant ball of recycled bi-product space trash?

Project Class: ES

Key Hole (optional):

Some things salvaged and/or manufactured in space could have a higher resale value back on Earth. For this purpose, it would be possible to include “film buckets” for the Terrestrial Retrieval of high-value payloads.One thought about making spacecraft capable of returning to the planet from space might involve converting Rocket Engine bells into heat shields.

Project Class: EEC

Steel Mill: (optional)

 a small steel mill for making rebar and billet, perhaps integrated into the smelter. Hopefully, we just grind everything down into dust for 3-D printing, depending on the tech.  Space Steel Mill sounds heavy and expensive.

Project Class: ES

Radioactive Waste Disposal:  Some particularly nasty things might have to be transported to a higher orbit, better yet, a heliocentric orbit. It would prevent terrestrial radioactive contamination, as was the case when a soviet spy satellite burned up over Canada.  Alternatively, they can be shipped to the ground for proper storage.

Project Class: ES

External Disassembly Area: (optional)

 Open space disassembly to take off solar panels or other long parts that won’t fit into the bay doors before entering the closed Disassembly area. It would consist of 2 robot arms and a docking area near the external fore docking port. The arms would be on a track for relocation next to bay doors. Some activities, such as radioactive fuel recovery, would also have to be done here. The area would not be open.  As a safety precaution, it would be encased in a retractable fine mesh net mounted on poles or an inflatable Bigalow space (non) habitation module.

Project Class: ES

Weight: low Cost: low

Fancy Net: (optional)

If we know where the station will be located, we can begin running salvage operations before the station is launched.  it would not hurt to build a Junkyard before launching.  It would make a portion of debris easy to recover and provide some materials for future use.  The project can start with a single semi-rigid cable tether to act as a temporary home while we set up shop.

Project Class: ES

Outhouse: (optional)

 Some work might require a human being. They are expected to work and live outside of the station in whatever craft they arrive in.  However, a life support locker and docking station might be useful in emergencies.  The  Locker would be minimal.  It would include basic life support, an airlock, a small workshop for sensitive tasks, and some controls for the station.  It would have some basic control systems, including the ability to shut down the station in case of a total loss of ground/space communication and a critical emergency. A single Bigelow expandable activity module might do the trick.  However, it might not. If more long-term human presence is required, a Bigelow B330 (Transhab)” multipurpose module should do the job nicely. A more secure and perhaps armored capsule might better prevent the loss of human life and could eventually be implemented.  It would honor existing space treaties meaning that in emergencies, Anyone who needs it would be able to use this facility without cost as a safe shelter.

Project Class EEC

No Buck Rogers, no space bucks:  If the project did have a long-term launch contract with space-x for Starship or If we had unlimited money, we could build a manned habitation area, including a control center, an airlock for EVA’s, residential quarters, and a bathroom.  The works.  They would probably be sparse, but if we went with a generic space-x design with changes for the control center only.  There is a chance they might be quite posh. The Airlock would likely be large, with space for storage of several specialized EVA suits and tools.  The entire habitation system would be located below the truss nader on the station to provide as much protection for the crew as possible from any mishaps or negative interactions with the more industrially oriented modules.

Project Class: NEN

Skyhook Recovery Tether (optional):

 A recovery arm tracked on a long rigid cable. The purpose of this cable is to help recover equipment from lower orbits and allow for a greater range of orbital options for transferring dead craft from LEO to a graveyard orbit and to the station. It would also create a buffer zone and greatly lower any chance of uncontrolled collisions with the station. Optimally this cable would be several KM long. Perhaps it could be used for propulsion if built as an electrodynamic tether. This tether could spin in order to transfer kinetic energy to electrical energy on capture. It was proposed for the project by my friend, Jay Queenin. It is also outlined in Neal Stephensonʼs science fiction novel 7 Eveʼs.

Project Class: ES

Telekinesis technologies (optional)

There are non-invasive ways to move objects in orbits, such as light using a solar sail, radio waves, radar, and lasers which push the object through space, or something more bizarre like an electron charging beam, with a negative electron catching plate. The lack of atmosphere allows all these technologies to operate better in space.   Most of these systems’ effectiveness diminishes at long range. However, none of them require any fuel.  If it becomes a primary goal to reduce fuel expenditures and launch costs, this is worth looking into.

Project Class: ES

Ground control Facilities:

This would not be a typical ground control facility.  It might be more similar to the unmanned drone facilities in use in the air force at Creech AFB than a standard NASA control center.  There would be an office with several programmers to automate as many of the salvage missions as possible. This area can be set up in a typical ground control format.  However, there will also be stations using some sort of full-body VR real-time interface.  This would allow for a direct hands-on approach to things and allow for the handling of unforeseen situations.  There would likely have to be some investment in human interface design.  One problem is the time delay in ground-to-space communications. Communicating with the ISS has a typical delay of three seconds or six seconds total for round-trip communication.  This will cause worse issues than the time delay with a live spacewalking astronaut.

Project Class: ES 

Security:

There was a James bond (ok, it was the gi joe cartoon) where the villain put a bunch of steel beams into space and threatened to shoot them back down at the Earth. Even if built without a Krusty, this plant would be perfect for the job as it is capable of both manufacturing and launching said beams. It shouldnʼt have to be like this, but security for the project would have to be high. There would need to be some defense system or an override shutoff system.  Perhaps a self-destruct button in case of hijacking, hacking or other mishaps. Detonation charges could be set on every satellite larger than x amount in tonnage in case of accidental de-orbiting.

Super Sensitive data: The Station would be capable of replacing computer systems for missions where encryption standards for telemetry and communication could be upgraded, enabling Some Satellites to be re-orbited. These contracts would have to be necessarily secret. 

Lunar Recycling: Matt Winner, a co-host on Startalk with Neil Degrasse Tyson and special guest Steve Wozniak in August 2022, mentions during the show, A recycling center on the moon.  It would happen immediately.  Even on the ISS, water and air are recycled.  The moon’s distance means our ability to ship resources is limited.  The low supply, high demand basic economics of the endeavor dictate that recycling would be a priority.  

However, he references a lunar recycling center on a  more industrial-grade scale for processing space junk.  There are a few fundamental problems with this.  One is the delta-V required to transition to lunar orbit and land.  It doesn’t require a huge amount of delta-v to get into lunar orbit, but landing is a problem.   It is exponentially less difficult than landing back on Earth. However, it still requires a decent amount of fuel based on mass for the landing process.

Space Station as an Advanced Biological Organism:

Pneumatic transportation tubes as the circulatory system.  The Arteries and Veins of the project
Cooling and heat pipes, power, and data cables as the nervous system.  The internal system of communication.

Robotics bay as the head (mouth, eyes, brain).  Where the materials are first processed.
Solar panels, batteries, and power supply as the heart.  The internal power generation system.
Furnace as stomach.  The heat augmentation process.
Sorting module as kidneys and liver.  Processing out the bad stuff.
Shredder and grinder as intestines.  Waste processing.
Manufacturing facilities as the butt.  Where the stuff comes out.
Thrusters and propulsion as the legs and feet.

– – – – – – – – – – – – – – – – – – – 

Missions:

1 Robotics repair station for servicing 
2 Recycling and manufacturing plant 
3 Extended operations junk removal and retrieval 
4 (Example) missions
5 Salvage missions

Alternates:
Plan B: Build the station directly out of the ISS

Mission 1: SERVICING AND REPAIR DRY DOCK ROBOTICS LAB: 

Robotics construction/deconstruction assembly repair bay Kerbal:

Kmass: 149t The 10m version Saturn 5 booster conversion was very difficult to launch.  Fortunately, this proposal does not call for launching any 149-ton repair bays into space. Instead, we will use a rocket booster that is already there.  It is an excellent first project with a massive gain.  It also sets a good precedent for the rest of the project.  Robots sold separately. After working through the mission several times in Kerbal, I realized that the best way to do this was to add a structural truss, such as the one on the ISS.   This truss has solar panels, heat radiators, batteries, several large reaction wheels, structural steel beams, and docking areas for future expansion.  It also has a small amount of Monopropellant to properly position itself for attachment to the converted rocket booster.  The truss is positioned underneath the main bay to prevent damage to any components during future docking procedures. Since building this, Kerbal has released the “Some Assembly Required” update, allowing kerbal engineers to do minor repairs and installations or move things around a bit.  However, there is a weight limit. You can only manipulate small components.  See the MSM for attempts at a ship construction and deconstruction bay.  It had a medium degree of kerbal success but is overkill with lots of docking ports and cargo storage.  However, only one engineer is needed for game use.

The Hermit Crab Approach represents the hard way.  There is an advantage though.  In philosophy, there are two schools of thought.  Short-sighted people will claim that the ends are justified by the means.  However, even in the vacuum of space.  The means are actually included in the ends.  Let me explain.  By building out a rocket booster into a robotic servicing bay, we learn the lessons we need to continue with the project.  If we can do this, Servicing and manufacturing other craft will be more manageable.  It also allows us to reduce or eliminate the need for a heavy-lift rocket by using several medium-lift rockets instead.  If necessary.

From the ground up:  It would be easier to build the robotics bay on the ground and launch using Starship instead of hermit crabbing an old rocket booster.  One major advantage would be the protection offered by Starship’s steel body rather than aluminum. Using Starship for the initial unmanned robotics bay would solve many problems.  Being able to assemble the entire bay as a functional entity on the ground could prevent many problems and make development and testing easier.  However, it would be less space.  It would be expensive.  Its development would be solely at the discretion of SpaceX.  In other words, YSpace would have to hire SpaceX to launch it directly.  SpaceX likely won’t have any extra starship launches anytime soon.  SLS could also launch the repair bay, provided extra rockets are built.  However, SLS costs upward of 4 Billion USD per launch, which would almost double the project cost. 

We could also delve into the realm of highly unlikely but wildly superior.  Launching the SpaceX Super heavy booster into orbit without Starship or any payload is possible.  The robotics lab could be built into the rocket directly inside the fuel tanks using the same drylab principles extensively discussed in mission one, but with most of the work done on the ground.  It would be the best solution.  It also relies on SpaceX again.

 Also, building on the ground and launching it would be too easy.  For the first mission, let us expand our ends included in the means, recycled booster robotics bay drylab idea. mm.  

Mission Requirements:  The mission as a stand-alone is intended to fix a gap in servicing, construction, and repair created by retiring the shuttle.  It can potentially pay for itself by repairing Envisat or some other large-scale, high-profile repair.  Another advantage of having an enclosed bay is the ability to house specialized workbenches for work on components or smallsats while having enough space for robots of varying scales to work on larger satellites. We can use the SL-8 RB 1976-108B (Saturn series).  It currently resides in an equatorial orbit.  This location would give us an excellent launch-to-weight ratio for future launches to the station.  A quick burn at its periapsis would put it into a nice circular low-Earth orbit similar to the ISS.   It would be a great way to kickstart the project. Go big or go home! 

SL-8 Statistics Length: 24m 
Circumference: 10m (or 6.6m) 
Area: 2513.27m (for 10m) 
Volume: 9424.77m (for 10m) 

Mission Goals: The plan is to successfully convert an expended rocket booster into a robotic repair station “dry habitat” The goal is to profit from satellite repair, refueling, and servicing in the short term while researching and improving the mechanical dexterity, versatility, and innovation in space robotics. Stand-alone storage and sorting facility and disassembly sub-system for future recycling and manufacturing phases.

We require one or more  RSV/OSAM  (Remote Servicing Vehicle)(On-Orbit Assembly Servicing and Manufacturing), spacecraft, and a cargo vessel to begin construction.  An uncrewed Soyuz Progress-M, Cygnus OA-X, Dragon, Dragon XL capsule, or Starship could do the job.  This cargo craft would carry the equipment for turning the salvaged rocket booster into a repair bay.  This will require a heavy launch vehicle and large faring.  

Said cargo would include hinges and openers for large bay doors, two docking ports that will be installed fore and aft, power hookups for the recycling station later, standard items such as reaction wheels, communications arrays, computers, and batteries. It might also include some track for moving materials and craft from one side of the bay to the other and other parts.  The launch would also include equipment for spacecraft repair,engine-facing robot arms – one DEXTRE, two standard Canada arms(or alternate), other small robotic arms, storage pods, a small number of transferable propellants, electrical cables, a power control system, replacement batteries for servicing, and an assortment of other gear and maybe some construction robots too.

Mission Steps:

1. The RSV or some scout craft would circle the booster while mapping and scanning it in 3D.  This allows us to check for damage, calculate docking maneuvers and exact a mission Plan. (Taken from DARPAʼs playbook).

2. The RSV then attaches itself to the rocket booster on the port side.  (the side without the engine). Any spin is stabilized.  

3. A hole is cut on the port side (the pointy end),  and a makeshift docking port is installed.  At this stage, it would be more of a docking hardpoint for the cargo craft than a permanent docking port.    The RSV then moves to its next staging area on the booster.  

4. The craft docks with the makeshift docking port on the offloads cargo with the help of humanoid robots such as Atlas or Fedor or the JAXA (Japanese Space Agency).  Perhaps all of the above until we determine which model works best, then improve, upgrade, and adapt for better use in industrial space.

5. The two fuel tanks that make up most of the space inside the booster have a very thin separator.  We can easily remove it to take advantage of the entire bay.

6. The robot worker connects power and other necessities from the cargo craft to the equipment inside the rocket booster.  The cargo craft deploys solar panels, communications, and other externals.  It will provide electrical and computational power, command, and control for the next steps.

7. A cleaning robot or robot in cleaning mode scrubs any residue inside the rocket booster.

8. Mounting hard-points to support the truss are mounted on the bottom.  These connectors are designed and positioned with structural integrity in mind.

9. One of our robot heroes then cuts large bay doors around 12m x 3m on whichever side of the booster we will consider from now on to be the top.  This action would be quickly followed by the installation of hinges and a bay door control mechanism.

10. The external CanadaArm or another robot arm would be deployed on the exterior of bay doors on the engine-facing side.

11. We would have to line the externals or internals of the robotics bay with insulation.  It would likely be (MLI) multi-layer insulation for passive thermal control and Kapton or Kevlar blankets for added passive thermal control and micro impact protection.

12. The robots would then install ammonia pipes and heaters for active thermal control over the inside-facing insulation layer.

13. The engine is removed. Then a structural wall with a docking port is placed on the engine side of the booster.

14. The uncrewed equipment craft remains docked and provides communications propulsion and navigation until equipment is set up and installed using the RSV in a future launch.

15. A second launch with an expandable structural truss structure is sent to the station.  This truss has docking ports fore, aft, and a few more on the bottom.  It has solar panels and heat radiation panels on the bottom pointed downward.  The truss has Several large reaction wheels spaced out along the entire structure.  The truss structure is then mounted and reinforced.  It will provide a great deal more power, structural integrity, and allow the bay to turn on its axis.

16. The bay would then spend some time building itself out, reinforcing bulkheads, and other structural improvements.   Perhaps a few steel I-beams could be run the entire bay length for structural and mounting purposes.  Then setting up workstations and other equipment, and building and installing proper connectors for future station modules and materials transport.

When we are done constructing, we can move on to the first step toward recouping investment and maybe a little RnR  (restoration, repairs).  The massively oversized bay will have to function for repairs as well as be used for storage.  It must be stand-alone and serve all station functions for the first few rounds of salvage and retrieval missions. It will serve as a base of operations for recovery missions, a safer environment for repairs, and a testbed for robotic space assembly.  After the rest of the station has launched, the bay can assist with further assembly.

When the assembly of the rest of the station is finished, this booster-turned-station module will focus on craft disassembly for recycling and, of course, the construction of new spacecraft. The facility will meet the entire scope of requirements for satellite servicing contracts.  If an RSV cannot tackle the problem independently, there will be a place to conduct advanced repairs at our newly created space dry dock.

The Robotics bay is ready to start servicing at this point.  It is probably time to send up another shipment of supplies.  Perhaps more solar panels, robotics, construction gear, batteries, Ammonia, cleaning liquids, RCS monopropellant, and anything else that didn’t fit within the size or weight parameters of our first medium-heavy launch.

The mass of this particular example booster would provide ample space for just about anything.  However, suppose we decide on a smaller booster. In that case, there is always the option to use something like the Bigelow Aerospace inflatable storage module for additional temporary storage or enclosed external construction/deconstruction.  The inflatable habitat could be handy for projects such as removing engines from rocket boosters.  It could also help prevent pieces from floating away while doing construction.

ISS Alternate proposal:  As the ISS ages, sections and modules will break beyond repair or become too unstable for human occupation.ISS:  It might be an easier sale to custom build a robotics bay for the ISS which can help restore and or recycle directly connected to the ISS, out of the ISS, or close to the ISS, and recycling many elements of the station.

This proposal has many advantages and cost-saving opportunities. For instance, it provides the ability for astronauts to assist in construction. A plentiful amount of material to work with allows for the benefit of not wasting as much expensive propellant for initial recycling and restoration projects. An early start would also help extend the life of the ISS by a few years.

If we can standardize the procedure, it becomes repeatable, and we can make several rocket booster spaceport adaptations.  Nanoracks floated the idea of making a wet lab for space tourism.  Perhaps we could build another robotics bay around the moon or mars.  We could make a manned Mars Earth cycler wetlab. They might be converted into initial ground habitats for the Moon colony.  Once we start converting boosters, nothing stops us from converting more boosters.

Space Shuttle: It might be possible to use the space shuttle design to build a stripped-down version to function as a robotics bay with no cabin, life support, heat shield, wings, engine, or fuel tanks.  It is outlined in the section MSM (manned service module)

Inventory:

Cygnus, Soyuz, or Dragon spacecraft
SL-8RB Saturn 5 rocket booster
RSV(s)
Lots of Robots.  Lots and lots of robots
2X Dextre robotic arms
BEAM expandable habitat for temporary scrap and parts storage (Bigalow Aerospace)
Bay doors cut from the top designated side of the rocket Booster
4-way external truss connectors
External Power Station and Solar connectors
Internal Power Station and Batteries
Port and starboard module connectors or temporary plug/wall
Piping for coolant and scaffolding
Scaffolding connectors
Misc. mounting brackets
Liquid ammonia coolant and cooling system
Oxygen for cleaning and auxiliary fuel for propulsion
Lubricants and spare parts for robots and satellite salvage craft
Internal optical lidar and 3D mapping system
Cameras, sensors, Internal and communication systems
Station computer control systems
Robot computer control systems
Air ducts, dust filters, and collection system

Data: 

Example Booster: SL-8 RB 1976-108B
LEO Altitude Specification: 1006 Km
Orbital Inclination and eccentricity: Apo 996km Per 958km Inc 82.93
Objective outcome: station stage 1, stand-alone servicing bay, profit
Launch vehicle: Delta Heavy(none left), Falcon heavy, Vulkan, SLS, Starship (or multiple launches)
Total weight: 25638lb (11629kg)
RSV weight 9920lb (4500kg)
Progress-M upper stage weight 15718lb (7130kg) (fully loaded with 2500kg worth of repair equipment) 

Ledger:
Cost for RSV: $7,000,000 (est)
Cost for progress-M (or similar craft): $10,000,000 (est)
Cost for DEXTRE and other servicing equipment: $5,000,000
Cost for Rocket and launch: $109,000,000
Cost for ground control facilities: $8,000,000 (est)
Cost for mission ground crew $10,000,000 per year (est)
Cost for Sales and legal $5,000,000 per year (est)
Cost for R&D and testing $4,000,000 (est)
Customer Acquisition Costs (and legal):
Total Cost for mission 1: $153,000,000 (in our wildest dreams)
Total Cost including Paid Salaries $432,000,000 (slightly closer)
Risk of human casualties: 0%
ROI for mission 1: 5 difficult repairs at $30,000,000+ each

Mission 2 KHRYSOS or A.R.R.M.S. (Automated Recycling, Repair, and Manufacturing Station): 

The Station itself Kerbal:

Kmass: 400+t There was one crucial takeaway from building this station over and over.  I built and rebuilt different versions of the station at least seven times before coming up with a design worth discussing.  I learned how important it was to standardize parts.  Oftentimes, in kerbal, things don’t work out as initially intended.  Keeping components highly standardized and self-sufficient allows for more versatility and adaptability.   The other key factor is stability.  Several steps were taken to reduce the shake.  The trusses that mount the solar panels have large reaction wheels to help reduce shake and allow for maneuverability.    There are also reaction wheels at the ends of each truss and several reaction wheels around the station core.   I bolted a truss to the bottom of the rocket booster turned robotic shuttle bay to the opposite side of the doors to prevent damage to the solar panels.  They also faced horizontally to the centerline, using the station as a shield.   While the station is not functional in the game, much thought went into designing the robot arms to work for maneuvers like berthing and moving station modules from one docking connector to another.   The First launch was the truss.  I tried several times to do a dual docking procedure.  Unfortunately, linking multiple docking ports at the same time was too difficult.  I cheated and launched the truss with the converted rocket booster from the ground.    The second and third launches were storage, armor, and docking modules.  The docking ports were positioned on the top of the armor/storage component.  The second launch contained a shredding component.   They also had large expandable tubes to connect to the industrial component below them.   The fourth launch was the industrial component.  It was connected to the lower truss module and was perfectly aligned so that the docking port was on the same plane as 2 of the storage modules on the outer side.  The Factory and other sensitive components are protected by the storage modules. The station has sufficient maneuverability, stability, and expandability.   The factory module features six ‘convertotrons’ for materials processing.

“The difficult, we do immediately.  The impossible takes a little longer”  – General Arnold in reference to the B-29 Production line in 1943.

The task is daunting.  We will need to test all the principles before expanding any heavy-lift vehicles.  Before any of the more significant components go up, we make a mini-factory small enough to fit in the robotics drydock.  Make the smelter the size of a toaster oven.  The shredder is the size of a blender, and the fine grinder is the size of a peppermill. The 2018 FABLAB concept uses elements that would fit in science racks on the ISS.  Step one can be an uncrewed continuation.

After the Robotics bay is finished, the truss is secured, and the module is mostly operational, the first launch of Mission 2 will be the specialized storage facilities.  These modules contain docking facilities, materials transport, and armor for the factory components.

The second launch will include the shredder, sorting system, furnace, refinery, the F.A.R.T. outgassing propulsion system, and all reclamation elements.  This part of the project will be expensive. It will take several years, an army of engineers, and at least 2.5 billion dollars to complete.  Unlike Mission one, there is no rocket booster we can convert into a drydock.  Most of this section is going to have to come from the ground. Much of the tech is untested. Some things do not exist at all yet.  It will require the adaptation of existing technology for space.  If we are lucky, a few technological breakthroughs could massively drive down the cost of construction.  It will need at least one heavy rocket launch. 

This project has lots of moving parts.  It won’t be easy.  Thankfully, uncrewed robotic assembly ensures no risk to human life.

Launch Vehicle: 2x Vulcan-Centaur (ULA) Falcon Heavy(SpaceX)

Weight: 34,900kg (76,900lb) 

Station components shredder, sorter, smelter, fine shredder, plastic 3d printer, metal 3d printers, KRUSTY power plant, Cooling heating docking communication, navigation, and propulsion. 

Cost of R&D and testing: $4,000,000,000 (guess)
Cost of plastic 3d printers 
Cost of metal 3d printers 
Cost of industrial shredder 
Cost of fine shredder 
Cost of the propulsion system
Cost of furnace
Cost of sorter Total
Cost of production: $4,000,000,000 
Cost of launch $1,000,000,000:

– – – – – – – – – – – – – – – – – – – 

Other Example Projects: 

Decommissioning the ISS: The ISS is scheduled to be deorbited sometime between 2024 to 2028.  There are plans to extend its life into the 2030s.   Let us hope that happens.  Eventually, someday it will have to be decommissioned.   It will amount to more than 150 billion dollars down in flames. This project would provide us with a fantastic alternative and allow the ISS to be reborn as something else.  There are elements of the ISS that are near impossible to launch and construct again. One particular element of our project would benefit greatly from using the ISS’s structural truss.

Recommissioning the ISS: If we work fast enough, this project will allow us to extend the ISS’s life with space manufacturing. As modules die, they could be recycled and made into new modules or parts for new modules.  We can also help with the fabrication and installation of new elements.

When dealing with the ISS, or modules from the ISS,  one issue is the immense amount of Delta-V required to move either the ISS or the recycling plant.  Moving most rocket boosters presents the same problem.   This project allocates funding to a series of spacecraft designed for the task.

(Example mission) –  Disassembly and Recycling of a Cubesat:  This is a stand-alone, easily budgeted mission that we can do tomorrow.  We should send A CubeSat to the ISS, disassemble it, and assemble it (with humans first).  The information is used to learn techniques in zero gravity that can then be done by robots in the future more safely and efficiently.  This would also help visualize how a zero-G workbench would operate. We want to see how astronauts twist their wrists and move their fingers.

Alternatively this will be done with humans and waterproof robots such as Atlas and JAXA’s GITAI.  It is done in  a pool of liquid using a fake CubeSat made of plastic that matches the buoyancy of the liquid (to mimic zero gravity). There is a pool at Marshall flight center in Texas built for precisely this sort of thing and another one in Huntsville, Alabama.

The data would be processed for a better understanding of how a robot would accomplish the same task in space.  

Nasa Prices for this mission as of 2019 (from TMRO news)
1 KG to space $20,000  
1 hour of crew time on the ISS $130,000
Mission Data processing $xxxxx
Total $150,000 + xxxxx

Humanlike robots such as Fedor, Atlas, or GITAI would start the disassembly process. As the components get smaller and smaller, more surgical-type robots would be employed.  There are insights from watching robots work on radioactive waste and bomb disposal. 

The greater and smaller our ability to disassemble things in the robotics bay, the less stress on the sorting system and the more purity we get from recycling components. 

Disassembly:  The first step is to remove the power supply and ensure all elements have been completely discharged and disconnected.  This is done to protect the components and prevent any accidental burnouts or actions.  After the power is disconnected, we remove the batteries.

The second step is to de-fuel the CubeSat.  It might require removing the thrusters as well.  They might be interlinked systems.  Depending on the fuel type, this is likely the most dangerous procedure.  So safety is a top priority.  We don’t want any rapid unscheduled disassembly or a chemical leak.

All external solar panels, communications, science, optics, and other externals are removed and stored.

The screws, spacers, nuts, and bolts are removed and sorted during disassembly.

Capacitors, transistors, heatsinks, and other small electrical components are removed and sorted for future use. 

As much plastic and metal as possible are removed from circuit boards.  

Carbon-based elements such as graphite and rubber are more finely separated for incineration.  

Reusable components:  Solar panels, radio antenna, nuts, bolts, screws, spacers, transistors, capacitors, resistors, diodes, inductors, batteries (sometimes).

Recyclable components: Plastic and Aluminum chassis and casings, nuts, bolts, screws, spacers, and batteries.

Incineratable components:
Carbon-fiber fuel tanks
Silicon PCBS (stripped)
Mylar/kevlar
Graphite
Rubber
Low-grade plastics

(Example Mission) Stem Research: Perhaps Tim Dodd, the everyday astronaut, could live broadcast a spacewalk to pick his community’s brain. He has an active and knowledgeable group of people who could potentially shed light on the issues and procedures.  Perhaps we could broadcast it live in a few university classrooms.  The actions taken by astronauts during the spacewalks for construction and maintenance can provide a great deal of insight into exactly how our robots would operate in the service bay.  The broadcast would help inform our research on robotic labor and space construction.  

(Example Mission) Hubble Robotic Repair:   Using OSAM-1 (Restore-L) or a similar spacecraft to robotically repair the Hubble Space Telescope, Envisat, or to provide an expensive yet feasible way to repair the much further out James Webb Space Telescope.  High-profile missions like these garner public support for the Satellite servicing industry.  

(Example mission) –  Building Junk Recovery Craft from Salvaged and restored Satellites:

The salvaged satellite will need an upgraded sensor and detection package and a communications package. It would likely require an upgraded hardware and software package.  It would need grappling and docking hardware.  Since it operates on old technology, it will probably have hypergolic fuel and need refueling.  The Telstar series satellites are prime candidates due to their size and fuel capacity. However, they are in MEO and GEO.  They would require a significant amount of fuel to capture. 

We are all for strap-on Ion thrusters brought up from the ground. However, that might not be a viable option. If it is, it gives us a good amount of Delta-V to play with.  

Shredding experiment:  This experiment seeks to build something practical for the ISS and provide data and answer questions about shredding in microgravity.  

1: how much heat does friction from the shredding process generate?
2: What are the dispersion patterns of the shredding process naturally?
3: How do we control that dispersion process in a vacuum?
4: Is there a way to have the shredder clean itself?
5:  What problems will we encounter with the cleaning process?
6: What shape teeth or knobs work best in microgravity?

As far as I know, there haven’t been any experiments on the ISS, Skylab, or Mir that attempt to shred or compact materials in Space.  Several furnaces, water heaters, 3D printers, and robots have existed in space.  Most of the elements in this project have been tested in space in one form or another.  This experiment is a rather simple one.  We send an industrial-grade paper shredder to the ISS, one of the models that can also shred credit cards.  At the bottom of this shredder would be an air sucker since there is an atmosphere in the ISS.  The end version of the shredder would likely have to work in a vacuum and might incorporate a screw to move materials. We equip it with several sensors to gauge heat and the motion of the newly shredded material.  

Almost all paper shredders on the market can handle credit cards and thin strips or sheets of aluminum.  Many can shred empty cans of soda.   

This experiment is designed to be practical.  It couldn’t hurt to have a paper shredder on the ISS.  It could help lower the waste footprint on the ISS, as well as aid in the disposal of sensitive or outdated written data.  

This experiment can be paired with a small trash compactor and incinerator.  While the overall  project doesn’t specifically call for either, the compactor could help provide data about a presser, which is used to create alloys.  The incinerator would help inform the development of the furnace.  They would both be useful on the ISS in the interim.

(Example Mission) Thermal experiments:

We can do small thermal experiments using sounding rockets.  Exos Aerospace can launch small payloads to test factory elements in zero-g and at various temperatures and G-forces 100km within 30 days for $6000 per launch. >1kg.

(Experiment) Internal systems transportation system: ISS closed loop pneumatic tube transportation system between the Russian and American segments, so they can exchange written notes without entering each other’s modules

– – – – – – – – – – – – – – – – – – – 

Salvage Missions:

The first salvage missions are Freebies.  They consist of obsolete satellites and boosters with fuel communication and control (FCC).  It is anything capable of making it to the station on its own propulsion.  The primary contenders include some Telestar, Starlink, One Web, and some spy satellites.  These are a big boon in space salvage operations.

Envisage (salvage or repair, not de-orbit) 

Some Boosters need to be recycled before a breach in the internal bulkheads causes the hypergolic fuel to mix and explode. This was the fate of the delta one and two rockets. They could also potentially be salvaged for fuel.

SL-16 First realistic kerbal salvage simulation

SL-16 Rocket booster (Soviet)  launched 3/26/93  Apogee 856km

Perigee 829km
Inclination 71 degrees
Mass 9 tons
No fuel no control not spinning
 *there are 17 more of these with very similar numbers
There are 2 more with a 99 degree inclination

Salvage Craft:

Space Tug
40 ion thrusters (80kn total)
Apogee 429km
Perigee 418km
Inclination 69 degrees
Xenon Fuel at start 35659/46080
Xenon fuel at return 27296
Start Mass 34t (45)
End mass 32t
Monopropellant 53/200
Station is at the space tug start orbit.
Salvaging Envisat (3/1/2002)
Perigee 764km
Apogee 766
Inclination 98.1 degrees
Mass 7.8 tons

Broken solar panels No fuel no communication no control not spinning

Salvage Craft
Space Tug
40 ion thrusters (80 kilonewtons total)
Apogee 429km
Perigee 418 km
Inclination 69 degrees
Xenon Fuel at start 28000/46080
XENON FUEL ON CAPTURE 16000
Xenon fuel at return 6000

Start Mass 32t (45)

End mass 
Monopropellant 30/200
The station is at the space tug start orbit.

Salvaging the remaining KH-11 Spy satellites:  The KH-11 Series is the same chassis as the Hubble Space Telescope.  There are two in particular which could work.  USA 161 and NROL-49 both travel in a counter-clockwise direction in a low Earth sun-synchronous orbit, which is optimal.  They both weigh around 17,000KG and have a graphite/epoxy frame.  These two spy satellites would give over 36tons to work with.  They are easier to dock with and transport than rocket boosters.  They might have fuel. The graphite is carbon-based and, therefore, would produce oxygen on incineration.  Alternatively, they might be converted into space telescopes. 

Salvaging Keppler:  Salvaging the Keppler Space Telescope would be difficult.  It is slightly bigger than 1 ton, so it is well within the size and delta-v range of a spacecraft like MEV, which has Ion Thrusters.  It is in a trailing orbit behind the Earth.  150 million km behind the Earth, to be specific.  It is in a near-Earth heliocentric orbit.  In order to get the telescope back into low Earth orbit, the salvage spacecraft would have to do several rotations around the sun to match orbits with Keppler.  There is a significant time/fuel factor.  Keppler itself has no fuel left.  It will be closest to Earth in 2071.

Salvaging Hubble:

Atlas Rocket Boosters A B C D (mercury) E F G H 1 2 2AS 3(2AR and 3B) and 5

Atlas Agena (GATV) upper stage.

Apollo and atlas centaur upper stages.

Thor, Redstone, and Jupiter Boosters. (All solid aluminum) 

Snap 10A (a nuclear reactor).

Fuel and propellant salvage missions.

Voyager GEOS-1 (which may explode).

EROʼs. (Easily recoverable objects).

Westford needles (copper) salvage.

Old Iridium Satellite network.

Build support beams from rocket casings and engines.

Build at least one support beam on a single rocket launch.

Recycling and repairing Starlink.

One last uncrewed space shuttle launch for permanent use in space recycled solar farm construction.

Decommission and recycle the ISS in 2028.

Saturn V 3rd stages S-IVB-205, S-IVB 206, S-IVB 207, S-IVB-208, S-IVB-210, S-IVB-502, S-IVB-503n, S-IVB-504, S-IVB-505, S- IVB-507. Many of these have heliocentric orbits and will require several years (average 50) for an easy chance of recovery. 

– – – – – – – – – – – – – – – – – – – 

Legal: 

All objects larger than a shoebox will need their owners contacted before any salvage operation takes place. However, it would make sense that debris from destroyed objects is subject to seizure and reuse by the salvage company.   In most cases, we are doing said owners a favor by removing their liability.

We will ask for but not require a detailed blueprint of the debris in question.  It includes the general external data, the current state of operation, and the design specifications of every internal component, down to the screw types.

The uncrewed station would comply with all articles in A/RES/47/68. It would be moved to a sufficiently high orbit on decommissioning (perhaps to be integrated at a much later date with whatever it is we are building out there at 36,000km…port of call. (MS21) 

Salvage responsibility reliability and liability, specifically fault liability and compensation. We have to consider international versus national laws and private businesses.

“Current regulations require that within 25 years of the end of the mission for the satellite, operators are required to de-orbit their spacecraft or, for higher orbits, to move to a specified graveyard orbit.  Launch operators are required to sign a space debris mitigation plan before they put anything into space” – Astroscale.

This project walks on a tightrope.  Space recycling involves secrets, lots and lots of secrets.  We do not seek out classified information.  However, there might be cases where we are unaware that something in the proposal is classified.  There are elements of the project that cannot be completed without some degree of information and cooperation that only the US military can provide.   
 
Space law is still in its infancy.  The laws are still soft and not enforced.  The UN, however, has drafted a 27-nation agreement for the long-term sustainability guidelines in space.

Raw ore: Station would likely have the ability to smelt near-Earth objects, small asteroids, and comets. It depends on how adaptable we make the recycling plant and disassembly bay.  

Orbital Real Estate

There is a lot of space in space.  A position on an orbital track might not be worth very much, but it still has some value, especially in geostationary orbit.  It might exist only in terms of physics, a math equation tracking an orbit in space that contains literally nothing, but there is still some value.  Every time we have to reposition a satellite. It costs something. Many optimal orbits are currently in use with defunct craft and debris. However, this is a much more significant problem in GEO as opposed to low Earth orbit. 

Advantages of berthing as opposed to docking:

 The main advantage of berthing over docking is the lessened risk factor of in-space collisions. Berthing is where the craft docks with a robot arm and is then pulled toward the station. In this case, the robot arm deposits the craft into the repair bay.

Advantages of working in a vacuum:

One advantage of working in a vacuum is our ability to process materials without fear of oxidation. It yeilds better quality metals on the whole. Additionally, it will allow for the safe storage of materials such as powdered aluminum without fear of catching fire or explosion. 

– – – – – – – – – – – – – – – – – – – 

Top 6 Biggest Problems and Solutions:

Problem 1: Delta-V:  The amount of fuel required to do a full salvage operation is extraordinarily high.  

Solution: Ion Thrusters:  Fortunately, in the past few years, there has been a fantastic amount of progress in developing plasma-based Ion thrusters that have a good specific impulse and would allow for several salvage operations on a single tank of noble gas.  The second solution is to refine a more traditional fuel on site.

Problem 2: Vibration and Procession:  For every action, there is an equal and opposite reaction.  If you move a large robotic arm in one direction, nothing stops the station from moving in the opposite direction.  Some modules, such as the shredder, would create a vibration.  It is also possible that it might set the station into an unrecoverable spin. 

Solution:  Massive reaction wheels:  The biggest reaction wheels might not be enough.  However, there is some promise in mounting them on trusses equidistant from the center of mass, allowing the station to compensate for any movement.  

Problem 3: Excess heat: Every watt of power used creates an equal amount of heat that needs to be dispersed.  

Solution: There are traditional solutions such as heat panels that disperse the heat out into space, along with pipes filled with liquid ammonia, which is how the internal living space of the ISS is kept cool.  There are currently new technologies in the works enabling better heat transfer to the radiators.  

Problem 4: Feedstock purity:  There is an expression in design, garbage in, garbage out.  

Solution: The first step involves building a workshop.  If functions using human-monitored hand disassembly using robots and advanced Materials separation and sorting methods.  Similar practices are used in modern recycling plants on Earth.

Problem 5:  Cleaning and maintenance: 

Solution: Liquid Nitrogen cleans well when applied and evaporated with heat.  

Problem 6: Debris Ownership:  Every piece of space junk down to the smallest paint fleck is owned by one entity or another.  

Solution:  Owners might be easily convinced to pass ownership of debris easily when reminded that with ownership comes liability.  

Problem 7 Sorting:

Probabilistic Risk Assessment: 

Risk Mitigation and tracking:  “Anything that can go wrong will go wrong fantastically in space,” -Dr. Sheyna Gifford from NASA.

Risk Classification A (estimated) 

Acceptable Risk: Very Low.
Priority: High national significance.
Complexity: Very High.
Cost: Very High.
Mission Lifetime: 20 years+.
Launch Constraints: Medium.
Re-Flight Opportunities: Significant.
In-Flight Maintenance: Planned.

Diplomatic Risks: 

Roscosmos, the ESA, or other space agency decides not to consider salvage contracts. The station could be regarded as a weapon. The station could be seen as a breach of the nuclear proliferation treaty.

Major risks and worst-case scenarios: 

• Accidents, Neglect, Malice, Distraction
• Nuclear-powered factory in space? What could go wrong? 
• Oxygen explosion as in Apollo 13, mitigation and control 
• Loss of communication 
• Equipment malfunctions 
• Collisions with docking craft such as the Mir Soyuz accident 
• Collisions with debris from pieces falling off of salvaged satellites 
• Collisions with space junk at high speeds 
• Chemical explosion 
• Pressure explosion 
• Uncontrolled re-entry 
• Satellite or rocket casing fuel explosion near the station or in the repair bay 
• Radioactive contamination in the repair bay 
• Cooling system failure reactor meltdown 
• Pressurized gas explosion 
• Dust breach, the canister of powder explodes, sending billions of metallic dust particles in all directions.
• Vibration damage
  Overheating 

Minor Risks:

• Communications issues.
• Command and control issues.
• Single system radioactive or biocontamination issues.
• Single system failure.
• Maintenance failure.
• Thermal stresses.
• Imperial metric conversion issues.
• Computer glitches.
• Fluid or gas line breaks.
• Severed wiring.

Contingency Planning, Going Cold: 

The station and its subsystems need to be able to be shut down mid-use in case of emergencies. Emergency shutdowns should cause no additional problems. The station should also be able to shut down everything at once, completely cut power if needed, and restart. This problem happened during The Rosetta mission. They had a complete loss of communication, turned off the spacecraft completely, and were able to remotely cold start the spacecraft with standby mode actions taken. 

The recycling Station would have to have the ability to change orbits immediately after any disaster in order to avoid colliding with its own debris. 

Operating most segments in an unpressurized vacuum partially mitigates the risk of a chemical explosion. 

Challenges: 

• Coming up with 25 billion dollars
• How much of phase 2 recycling/manufacturing has to be sent up pre-fabricated 
• How do we minimize re-supplies? 
• How much can be assembled in space? 
• How small can the recycling/manufacturing plant be made with cost efficiency in mind? 
• How can we change the orbits of debris cheaply?
• Capturing objects in polar orbits and moving them to an equatorial orbit
  Capturing Objects in rotation, matching rotations Stopping the procession
• destroying or capturing dangerous micro-objects 
• Cleaning the shredders 
• Cleaning the furnace 
• Cleaning the 3d Printers 
• Cleaning in General 
• Cleaning without using water 
• Recycling cleaning water and water in general
  Waste heat
• Moving materials through the shredder in zero gravity
• Station maintenance 
• Oiling parts, keeping shredders and grinders sharp, replacing gears, fuses, wires, etc. Station repairs
  Moving materials from system to system within the station 
• How to move particles without chemical propellant 
• Development of Micro factory technologies which can also operate in zero-g. 
• The KRUSTY power plant has yet to be effectively tested in space. 
• Removing paint 
• The Mass driver waste disposal system and industrial outgassing propulsion system (FART) doesnʼt exist yet. 
• Scrubbing and/or disposing of radioactive buildup (irradiation)  acquired on the spacecraft’s exterior. 
• Disassembly of craft without transferring radioactive contamination from the exteriors of satellites and spacecraft into the repair bay and tools inside 
• Security for Disassembly in secure mode, 
• CyberSecurity, how to NOT reveal information about the guts of specific Satellites and Spacecraft 
• Thermal and vacuum testing for the larger components.
  It might not look pretty.

– – – – – – – – – – – – – – – – – – – 

– – – – – – – – – – – – – – – – – – – 

Configuration Control Board: (CCB)(temporary) 

Jacob Bouchard – Temporary project manager 
Mary Reph (NASA) (SSPD)
Isaac Arthur (SFIA) – Media Presenter 

SEMP (System Engineering Management Plan) 

Phase A Concept Study – 2021-2023 
Phase B Preliminary Design – 2021-2025 
Phase C Critical Design and Build – 2025-2027 
Phase D Integration Testing and Launch – 2027-2029
Phase E – Restoration and Refueling Missions – 2030 
Phase E2 – Recycling And Manufacturing – 2030 – 2050+

WBS (Work Breakdown Structure) and PBS (product breakdown structure) 

Engineering classification systems and subsystems 
Inventory identifier cost account number 
Relationships and Integration 
(TPM) Tracking spacecraft mass 

Network Schedule 

Activity Description 
Activity Duration 
Critical Path 
Precedence 
Diagram 
Gantt Chart. (Timeline for System Assembly) 
Design, Fabricate, Test 

– – – – – – – – – – – – – – – – – – – 

“According to Space Tech Analytics’ Space Tech 2021 report, there are more than 10,000 private space tech companies and 5,000 leading investors. The best known, of course, is SpaceX but the corporate space arena has expanded. It will continue to do so in the coming years” –Thediplomat.com

Proposed Contracts with Corporations and individuals:

This is what the proposals commercial partner Dream Team would look like

SpaceX  – Launch services, batteries

Northrop Grumman – Salvage spacecraft and space tug

Lockheed Martin – Space manufacturing elements

Firefly- Launch Services, Manufacturing services

Rocketlab – Launch services

Privateer – Debris database 

Tethers Unlimited – salvage spacecraft and recycling technology

Redwire – 3D printing and additive manufacturing

Other Relevant Space Companies  

Redwire (Made in Space): primary developer for FABLAB

NASA: Can provide funding, launch services, engineering, etc.

ESA: Can provide funding, launch services, engineering, etc.

Compass: Builds thermal sensors for space use. (and other shit) 

SSL Space: Builds Satellites. They also built the Restore-L (now OSAM-1) LEO servicing vehicle. 

Maxar: Won The DARPA RSGS RSV contract and turned it down, citing cost overruns. 

Nanoracks:
Colorado School of Mines graduate space resources classes

Arizona State University Space program.  They did the psyche class

Georgia Tech Cross systems integration
DARPA: without DARPA’s fantastic research, this would not be even remotely possible.
United States Merchant Marines:

United States Air force and space force: particularly the 54th wing.

The United States Space Force: Their technology department Spacewerx and the Orbital Prime directive.  

This proposal was started in 2018.  When I searched on google for “space recycling,” nothing came up.  There were no active plans for space debris removal.  The shuttle had already been retired, so there were servicing vehicles in space except for perhaps the XB-37.  In 2019 I finally heard the term space recycling in a lecture from the Netherlands that had about 20 attendees and 200 hits on youtube.  The presenter stated that space recycling was not remotely possible.  

Since then, there have been countless plans, proposals, and startups.   We adhere to the Team Space mantra and fully support every endeavor.  However, that isn’t how capitalism works.  Here is a comprehensive list of companies and projects.  It has been said that space is a team sport.  Here is the team.  

Orbital Prime:  More backdating.  Space Force didn’t exist when the proposal was first submitted to NASA.  Before Space Force, the air force handled most space debris tracking and traffic management.  The U.S. military is still responsible for most of it but is spread across two branches now.  Orbital Prime is Space Force’s debris capture and space recycling plan.  They are currently taking proposals (Feb 2022).  This proposal does not qualify because Yspace barely exists and isn’t a licensed aerospace defense contractor.  However, we sent it over anyway.  They seemed to like it.

Northrop Grumman: Even more backdating.  One of the things I did find in my first year of research was the Northrup Grumman MEVS (Mission Extension Vehicle). It had a 2021 launch date but got pushed up a year and was launched in 2020 instead.  Grumman is well-funded and has a great track record.  They also make the Cygnus Cargo capsule.  Unfortunately, the Antares rocket is mostly developed in Ukraine.  There might not be many left.  Grumman operates from their launch facilities in Wallops Island, Virginia.    

Lockheed Martin:  Lockheed doesn’t release much info about their future space plans for space infrastructure, but as of Feb 2022, they have a few in the works.  The one most relevant to this proposal is their Cubesat servicer.  They also have done work with refueling in space and a furnace module which was adopted early in this project’s development.  (more info needed. It might be classified)

Boeing:  They built the first servicer, the space shuttle. However, their focus has shifted toward other projects.  It does not appear they currently have an active role in orbital servicing, space debris, space recycling, or space manufacturing.  They had a hard few years with the failures of their manned capsule starliner, the recall and grounding of the 737 Max, and the delay of SLS.  Let us hope they turn it around and have the resources to commit when the time comes.

Redwire – Redwire has recently purchased several early innovation companies that built prototype mini manufacturing facilities for the ISS designated the FABLAB project for NASA.  These companies include ‘Techshot’, which 3D prints human organs in microgravity, and ‘Made in Space,’ who designed and tested several plastic 3d printers for microgravity. They purchased a few other companies as well.

Tethers Unlimited:   Based in Seattle, Washington, Tethers Unlimited has focused on space recycling since contact.  They have been quiet about whatever they are working on. 

Orbit Fab:  Supported by SpaceX.  They have already launched a refueling depot into space.  

Privateer:  Privateer was started in late 2021 by Alex Fielding and Apple legend Steve Wozniak.   They have brought on Moriba Jah.  He has been working on space debris for a decade and is often quoted in this paper.  They have the brains, but It doesn’t seem like they have much funding yet.

Leo Labs: also focuses on space debris tracking.  They operate four ground control stations and hope to expand for better coverage of space in the future.  

E-Space started in 2022. They are very new.  The CEO, Greg Wyler, is French but also has offices in the United States.  They have received a seed funding investment of 50 million dollars.  They plan on building communications satellites that collapse on collision like a car’s crumple zones.  After the collision, the satellites are supposed to de-orbit, carrying the suspect debris with them.

(That Australian Company) 2021  I forgot their name would have to add it.   They have an interesting proposal that sounds a bit like this one, well, not really, but the idea is to make specialized spacecraft that run on specialized fuel rods that can be easily made in space using an aluminum derivative Ion thruster fuel rod.  They are partnered with Adastra

Adastra – The makers of the ELSA-D Remove debris spacecraft

Relativity Space- 3D prints their rockets.  They are the best at additive manufacturing in Aerospace.  They have had to develop their own techniques to print larger components without warping.  Their printers are capable of printing a large range of Alloys.   Some of which they have dialed in for the intense stresses involved in rocketry.    They use a 3D printer called Stargate, the world’s largest metal 3D printer.  2 former blue origin employees created Relativity Space.  Jordan Nune and Tim Ellis.   Their rockets are Terrain 1, and Terrain R.  The Terrain R will be able to lift 20 metric tons to low Earth orbit.    The 3D-printed rocket engine is called Eon.    Operated out of California, they are valued at 2 Billion Dollars. It will launch into orbit before Blue Origin.    more info about relativity space and 3d printing custom components with mixed alloys.   If they fulfill their mission statement, their launch costs per kg will be lower than any other launch provider.

Firefly

Space forge – Manufacturing in space.

Astroscale – 

GITAI – Robotics and robot workers.  They are Japanese and work closely with JAXA.  Their robots have been tested on the ISS.  They show the most promise for our servicing robotics bay.  

– – – – – – – – – – – – – – – – – – – 

Steps needed to pass NASA PDR (Preliminary Design Review) phase C/D 

Very Vague Business Estimates: 

Total Cost: $29,602,760,000
Three factors of employee: federal, private, and military

Control Staff:

CEO – Someone with humility, who will motivate and get the job done on time and on budget.
CIO – Someone with links to the intelligence community who is also a tech genius.
CFO – The iceman, not into crypto, well connected in the financial world.
COO – The get er done guy – gung ho, possibly ex-marine, with a sense of humor.
Head of HR – practical, sympathetic, good reader of people, no bullshit.
Head of PR – A righteous social media wizard liked by all with an environmental bent. (like Tim Dodd)
Government Liaison – Lawyer with ties to the government, a former lobbyist for something like coffee.
Military Liaison – Someone with extensive work in Veteran Affairs and an engineering background.

General Staff:

Physicists who specialize in orbital mechanics. 
Chemists – Physical chemists with a specialization in metallurgy.
Aerospace mechanics, Auto mechanics, electricians, and plumbers – calling all space MacGyvers.
Robotics Engineers
Engineers with computer programming experience with robots
Integration specialists 

Considerations and classifications: Appendix Of Project-Specific Acronyms:  

These classes are used internally to establish a budget based on human resources. It functions as a rough calculation for the main element of the budget, people.  It helps determine how many, how long, and who.

Project Classes:  

Some things will have to be assembled entirely from scratch. It is an expensive process. Some items can be built off a template using previously existing hardware. Some things can be retooled from other projects with minimum cost. Project and subproject outlines will follow with a classification E for engineering.

“ES” for engineering from scratch. It encompasses the design and testing of the shredder, Smelter, refiner, and other in-space industrial elements. Building things that have not been tested in space except as a hypothetical “Yes, this could probably be a done” scenario.

Average engineering and analyst and scientist staff required: 64 employees.

“EEC” Engineering from Existing Components. A system already designed, such as modules and components for Mir, Skylab, the ISS, or Lop-G. Or it could even be something as complex as the augmentation of KRUSTY kilo power or solar hydrogen equivalent to generating more heat for the furnace than electricity. 

Average engineering and analyst staff required: 32 employees.

“NEN “ No Engineering Necessary. Someone has already built this. However, it still has to be purchased and integrated.

Average engineering and analyst staff required: 8 employees.

Engineering from Scratch 64-person development team:

One year staff cost $9,720,000

20 year staff cost $194,400,000

One lead designer
One Project Manager
Two Thermodynamics engineers
Five mechanical engineers
Two electrical engineers
One Software Systems Engineer 
One Project Verification And Validation Engineer 
One End to end information Systems Engineer
One Instrument System Engineer 
One Systems Operations Engineer
Two systems cross-compatibility engineers
One draftsman/ illustrator / artist
Three Human Resources overseers
Three resource analysts
One schedule analyst/coordinator
Ten staff assistants and Jrs
One Lead test conductor
Two system-specific scientists
Two Hardware and Software Quality Assurance Engineers 
Five Construction and testing Technicians 
Five Integration engineers
Six Computer programmers
One Lawyer
One Accountant

No Engineering Necessary 8 person development team:

One year staff cost $810,000

20 year staff cost $16,200,000

Three Integration engineers
One Computer programmer
One Lawyer

Some Engineering Necessary 32 Person Development team:
1 year staff cost $2,430,000

20 year staff cost $48,600,000

Three Integration engineers
Two Computer programmers
One Lawyer
Three Staff assistants
One Human Resources Secretary
One Electrical engineer
Two Mechanical Engineers
One resource analyst
One system-specific scientist

Total necessary operational staff: 

(This is augmented from the psyche mission coursework)

Big Dreamer – Me – $75,000 (yr) 
Principal Investigator 
Project Scientists Systems Manager – $120,000 (yr) 
Inter-organizational coordinator – $80,000 (yr) 
Ground Data Systems Analyst – $70,000 (yr) 
Director of mission operations – $100,00 (yr) 
Flight director – $100,000 (yr) 
Assistant flight director 
Flight Activities officer 
Network Controller 
Business Manager 
Staff Assistant 
Resource Analysts 
Schedule Analysts 
Contract Manager 
Project Manager
Project System Engineer 
Project Staff Assistant 
Project Business Manager 
Subsystem Design Engineer
Project System Engineer(s) 
Project Software Systems Engineer 
Project Verification And Validation Engineer 
End to end information Systems Engineers 
Planetary Protection Engineer 
Contamination Control Engineer 
Launch Systems Engineer 
Launch Approval Engineer 
Safety Engineer 
Environmental Requirements Engineer 
Magnetic Control Lead Reliability Engineer 
Electrical, Electronic, and Electromechanical Parts procurement and Engineering Hardware and Software Quality Assurance Engineers 
Payload System Engineer and Manager 
Instrument System Engineer 
Instrument Electrical Engineer 
Instrument Test Engineers 
Instrument Technicians 
Instrument Mechanical Engineers 
Instrument Thermal Engineers 
Flight Systems Engineer 
Flight systems Support Engineer 
Cognizant Engineer 
ThermoDynamics Engineers 
F.A.R.T Engineer 
Nuclear Power Engineer Nuclear 
Waste Disposal Engineer 
Nuclear Fuel Recycling Engineer 
Product Delivery Manager 
Mission Assurance Manager 
Mission System Manager 
Science Systems Engineer 
Spacecraft Operations Engineer 
Planning and Execution Systems Engineer 
Lead Test Conductor 
Electrical and Mechanical Technicians Assembly, 
Test and Launch Operations Manager 
Ground Date System Manager 
Finance Manager 
Instrument Resource Analyst 
Instrument Information Management 
Mission Manager 
Program Manager 
Program Analyst 
Mission Planner 
Mission Designer 
Mission Design Manager 
Mission Program Executive 
Mission Program Scientist 
Navigation Engineer 
Optical Positional Navigator 
Director of Communications 
Public Engagement Representative 
Media Relations Representative 
Artists 
Web Designer 
Social Media Manager 
Management Support Assistant 
10 flight controllers – $70,000 (yr) 
20 instrumentation support staff – $60,000 (yr) 
10 Sales and legal Staff – $70,000 (yr) 
20 Hr and payroll staff – $45,000 (yr) 
2 Maintenance and Janitorial Staff – $28,000 (yr) 
100 College Interns $10,000 (yr) + course credit 

Name of Project	class	Emp	in House?	Contractor	contractor cost	Total Cost
MEV-1 RSV	NEN	8	No	Northrop Grumman	$50,000,000	62,200,000
Restore-L RSV	NEN	8	N0	Maxar	70,000,000	82,200,000
LEO Knight RSV	NEN	8	No	Tethers Unlimited	50,000,000	62,200,000
SPS Single Person Spacecraft RSV	NEN	8	no	Genesis	10,000,000	22,200,000
Ares Second Stage Tug	NEN	8	no	ULA	40,000,000	52,200,000
X-37b RSV	NEN	8	no	USAF	60,000,000	72,200,000
Linuss RSV	NEN	8	no	Lockheed Martin	10,000,000	22,200,000
APIS Mining MiniBee	NEN	8	no	Trans Astra	70,000,000	82,000,000
Remove Debris	NEN	8	no	SSTL	10,000,000	22,000,000
ClearSpace	NEN	8	no	Clearspace	10,000,000	22,200,000
Elsa-D Space Debris	NEN	8	no	AstroScale	10,000,000	22,200,000
Retrieval JunkBot	ES	64	Yes	Yspace	0	194,400,000
Tugboat Garbage Truck	ES	64	Yes	Yspace	0	194,400,000
Podship	ES	64	Yes	Yspace	0	194,400,000
ScoutCraft	ES	64	Yes	Yspace	0	194,400,000
Space Clip	ES	64	YEs	Yspace	0	194,400,000
Fuel Tanker	NEN	8	No	Space X	200,000,000	212,200,000
Catfish Small Debris Collector	ES	64	yes	Yspace	0	194,400,000
NanoBots	ES	64	yes	Yspace	0	194,400,000
Burndy Construction Craft	ES	64	yes	Yspace	0	194,400,000
MSM (Manned Service Module)	ES	64	Yes	Yspace	0	194,400,000
MSV (Manned Service Vehicle	ES	64	YES	Yspace	0	194,400,000
CanadaARM2 (SSRMS)	NEN	8	no	MDA Corporation	50,000,000	62,200,000
RMS Remote Manipulator Arm	NEN	8	no	CNSA China	50,000,000	62,200,000
ERA European Robotic Arm	NEN	8	NO	Space Office	50,000,000	62,200,000
Kraken Small Robotic Arm	NEN	8	No	Tethers Unlimited	10,000,000	22,200,000
Strela Russian Robotic Crane	NEN	8	No	RosCosmos	25,000,000	37,200,000
Fedor Russian Robot	NEN	8	No	Emercom of Russia	20,000,000	22,200,000
GITAI Japanese Robot	NEN	8	No	GITAI	30,000,000	42,200,000
ATLAS Robot	NEN	8	No	Boston Dynamics	20,000,000	32,200,000
Daisy Phone Recycling Machine	EEC	32	Yes	Apple Computers	50,000,000	98,600,000
Devinci Surgery Robot	EEC	32	Yes	Intuitive	2,000,000	50,600,000
Fanuc Industrial Robots	EEC	32	Yes	Fanuc	1,000,000	49,600,000
Guardian GT Robotic ExoSkeleton	EEC	32	Yes	Sarcos	15,000,000	63,600,000
Spot Dog Robot	EEC	32	Yes	Boston Dynamics	100,000	48,700,000
Ocean-1 Deep Sea Worker	EEC	32	Yes	Stanford University	300,000	48,900,000
Hadrian X Construction Robot	EEC	32	Yes	FBR	300,000	48,900,000
RRP Redwire Regolith Print	NEN	8	No	Redwire	3,000,000	51,600,000
Andos Nomad Bomb Disposal	EEC	32	Yes	Northrup Grumman	2,000,000	50,600,000
Samsung Bot Handy	EEC	32	Yes	Samsung	100,000	48,700,000
Tesla Robot	EEC	8	No	Space X	5,000,000	53,600,000
Mini Crawler	ES	64	Yes	Yspace	0	194,400,000
Mr Clean Robot	ES	64	Yes	Yspace	0	194,400,000
DryDock Robotic Workbay	ES	64	Yes	Yspace	0	194,400,000
Robotic Workbay Workstations	ES	64	Yes	Yspace	0	194,400,000
Shredding Module	ES	64	Yes	Yspace	0	194,400,000
Fine Grinder	ES	64	Yes	Yspace	0	194,400,000
Sorting Module	ES	64	Yes	Yspace	0	194,400,000
Furnace Module	ES	64	Yes	Yspace	0	194,400,000
Refinery	ES	64	Yes	Yspace	0	194,400,000
FART Propulsion	ES	64	Yes	Yspace	0	194,400,000
Solar Power	NEN	8	No	Boeing	40,000,000	52,200,000
KRUSTY Nuclear Power	NEN	8	No	NASA	15,000,000	31,200,000
Batteries and Power Management	ES	64	Yes	Yspace	0	194,400,000
Refabricator	NEN	8	No	Tethers Unlimited	10,000,000	26,200,000
Trussleator	NEN	8	No	Tethers Unlimited	30,000,000	46,200,000
Lumivec Multi Material Printer	NEN	8	No	Interlog Corp	20,000,000	36,200,000
Relativity Space 3D printers	NEN	8	No	Relativity Space	20,000,000	36,200,000
Additive Manufacturing Facility (AMF)	NEN	8	No	Redwire	20,000,000	36,200,000
GE Aviation 3D Printers	EEC	32	No	General Electric	1,000,000	49,600,000
ESAM Large Format Printer	NEN	8	No	Redwire	10,000,000	26,200,000
Archinaut-1	NEN	8	No	Redwire	20,000,000	36,200,000
Human Organ Printer	NEN	8	No	Redwire	10,000,000	26,200,000
Carbon Fiber Recycling	ES	64	Yes	Yspace	0	194400000
Titanium Recycling	ES	64	Yes	Yspace	0	194400000
Battery Recycling	ES	64	Yes	Yspace	0	194400000
Recycling Solar Panels	ES	64	Yes	Yspace	0	194400000
Recycling PCB Circuit Boards	ES	64	Yes	Yspace	0	194400000
Recycling Nitro Cellulose	ES	64	Yes	Yspace	0	194400000
Recycling Polyurethane	ES	64	Yes	Yspace	0	194400000
Recycling Recycling Chemicals	ES	64	Yes	Yspace	0	194400000
Alternative Recycling	ES	64	Yes	Yspace	0	194400000
Waste to Energy	ES	64	Yes	Yspace	0	194400000
Kinetic to Energy	ES	64	Yes	Yspace	0	194400000
Waste to Fuel	ES	64	Yes	Yspace	0	194400000
Growing Fuel	ES	64	Yes	Yspace	0	194400000
Converting Fuel	ES	64	Yes	Yspace	0	194400000
Advanced Materials	ES	64	Yes	Yspace	0	194400000
Gas Compression and cooling	ES	64	Yes	Yspace	0	194400000
Large Scale Manufacturing	ES	64	Yes	Yspace	0	194400000
Centrifuge	ES	64	Yes	Yspace	0	194400000
Structural Support Truss	ES	64	Yes	Yspace	0	194400000
Generic Station Hub and Connector	ES	64	Yes	Yspace	0	194400000
Reaction Wheels	EEC	32	Yes	Yspace	0	194400000
Armor	ES	64	Yes	Yspace	0	194400000
Powder Storage	ES	64	Yes	Yspace	0	194400000
Gas Fuel Storage	ES	64	Yes	Yspace	0	194400000
Cryogenic Fuel Storage	ES	64	Yes	Yspace	0	194400000
Nuclear Fuel Storage	ES	64	Yes	Yspace	0	194400000
Nuclear Waste Storage	ES	64	Yes	Yspace	0	194400000
Finishing Module	ES	64	Yes	Yspace	0	194400000
Materials Cleaning Module	ES	64	Yes	Yspace	0	194400000
Muck Resistance	ES	64	Yes	Yspace	0	194400000
External System to system transportation	ES	64	Yes	Yspace	0	194400000
Internal Factory materials Transportation	ES	64	Yes	Yspace	0	194400000
Docking Ports	NEN	8	Yes	Yspace	0	16,200,000
Cooling and thermal Control	ES	64	Yes	Yspace	0	194400000
Self Repair	ES	64	Yes	Yspace	0	194400000
Gas Station	ES	64	Yes	Yspace	0	194400000
Command Module	ES	64	Yes	Yspace	0	194400000
Communications Module	ES	64	Yes	Yspace	0	194400000
Programmable Control Interfaces	ES	64	Yes	Yspace	0	194400000
Realtime Control Interfaces	ES	64	Yes	Yspace	0	194400000
Sensors	ES	64	Yes	Yspace	0	194400000
Artificial Intelligence	ES	64	Yes	Yspace	0	194400000
Maneuvering Thrusters	NEN	8	Yes	Yspace	0	16,200,000
Detonation Charges	ES	64	Yes	Yspace	0	194400000
Solid Slag Disposal	ES	64	Yes	Yspace	0	194400000
Nuclear Waste Disposal	ES	64	Yes	Yspace	0	194400000
Outhouse	ES	64	Yes	Yspace	0	194400000
KeyHole	ES	64	Yes	Yspace	0	194400000
Telekinesis Technologies	ES	64	Yes	Yspace	0	194400000
Structural Bracings	ES	64	Yes	Yspace	0	194400000
Liquid Pressurization	ES	64	Yes	Yspace	0	194400000
Ground Control Facilities	ES	64	Yes	Yspace	0	194400000
Support Staff	–	200	–	Yspace	0	648000000
Total		5504			$1,069,800,000	$17,832,960,000

– – – – – – – – – – – – – – – – – – – 

YSPACE Logos:

Version Control:

V1 – August 2018 (total crap)

V2 – September 2018  (learning experience)

V3 – November 2018  (first concrete proposal)

V3.1 – December 2018 (Nah still total crap)

V3.2a – March 2019 (crap)

V3.4a – May 2019 (crap)

V3.5a – July 2019 (crap)

V3.8a – November 2019 (embarrassing) Also long covid brain fog unable to write for a year.

V4.0 – January 2021 – Kerbal space program experiments

V 4.1 – February 2021  –  Juggling lessons revisions

V 4.1.1 – March 2021 – Spelling and grammar round 1

V 4.1.2 – April 2021 (Earth day) – At least 10,000 small changes and fixes, new mission two examples, environmental opportunities, and terrestrial improvements.  Still scattershot but better.

V 4.1.3 June 2021 – small changes font changed to 12 point single spaced more terrestrial improvements.

V 4.2 December 2021 – Cohesion fixes, better images, truss information added, armor added, cooling, 2020-2021 advancements, 3000+ copy edits, 16 pages of content removed  4.2 specific Kerbal Kristmas present added at the end. Environmental opportunities moved to the bottom.  

V 4.3 December 2022 – Added five-page synopsis.  Removed another 20 pages of content.  Including the kerbal kristmas mission and a large chunk of irrelevant climate change information.  Expanded Internal materials transportation and storage section.  Expanded manufacturing section, armor, more.  Added a sorting and cataloging section.  5000 changes, moves, and fixes.  Restructuring of the document.  New index.  Kerbal example missions.

Relevant links: 

IADC – Inter Agency Space Debris Coordination Committee
Mohiba Jah UT Austin – Space debris tracking system  
Stuff in space – Database of everything in space
LeoLabs – Another Database of everything in space
Celestrak – Provides satellite position data in raw format
Skylab materials science experiments  pages 557, 558, 562  
Nasa – Visual Breakdown of the ISS
(MSS) Mobile servicing system Interface control document
Universe today – Chart with basic info about the duration of space junk and degrading orbits
Harvard – end of life disposal of Geostationary satellites 
Popsci – Darpa’s RSVs 
Darpa – Project Phoenix crewed service vehicle  
Wired – Robots fixing satellites  
Cnet – Space debris capture technology  
ESA – Magnetic space tug for dead satellites
Popular Mechanics – Satellite crash report 
Vox – Article on space junk  
Popsci – Article on OSAM and Restore-L  
Wired – Steel 3D printers  
Meteorite Orbits –  Database of known meteorites  
Nasa – Orbital Debris  
Vox – Another article on space junk  
ULA – Vulcan Centaur rocket 
Wikipedia – Soyuz 6  
Nasa – Research experiments  
We are the mighty – Rods from god  
Fraser Cain interview, Alex Ignatiev – Manufacturing on the moon 
Space News -Space force expands space debris database. 
Interesting engineering – DIY Plastic bottles to filament
Washington Post – Maine becomes the first state to shift costs of recycling from taxpayers to…
Space News – Orbital Debris is a lot like trying to solve climate change
Space shuttle – Variations that never happened
NBC News – Burning deceased humans will create electricity
ADN – The story of Anchorages trash
Denver 7 –  A solution to the plastics no one wants and can’t be recycled
Inside Deevs – Tesla’s new batteries will be zero waste
Scott Manley – Why Commercial Space stations are the future NASA wants.
Spacenews – Space force launches Orbits Prime to spur the market for On-orbit Services.
Salon – Earth’s Space Junk Problem Is Getting Worse
Darkspace – Kessler Syndrome
Jonathan McDowell – Space police
MSN – 100 years of robots 

Sounds:
INXS – Don’t Change
Midnight Oil – The Dead Heart
Peter Schilling – Major Tom (Coming Home) (Official Video)
Led Zeppelin – Wonton Song
HEAVY METAL-Don Felder

Youtube Literary and Sci-fi References: 

TMRO News.
Tim Dodd – everyday astronaut.
Scott Manley.
Mining in the sky – John S. Lewis.
Issac Arthur – SFIA.
The Curious Droid.
Joe Scott – Answers with Joe.
Seveneves – Neal Stephenson.
Neuromancer – Willam Gibson.
Liquid Science – GZA (S1 E5 Musicʼs future).

– – – – – – – – – – – – – – – – – – – 

Appendix of Acronyms:

Y* – Why why why!
RRR – Restore, Reuse, Recycle.
LEO – Low-Earth Orbit.
MEO – Medium-Earth Orbit.
GEO – Geo-Stationary Orbit.
NEO – Near-Earth Object.
ERO* – Easily Recoverable Object.
STEM – Science Technology Engineering Math.
ROI – Return On Investment
RPO – Relative Proximity Operations.  A term for maneuvers during a close encounter with another object in space.
CRP* – Collect Recycle Profit.
FCC* – Fuel Communication, Control.
Kg – Kilogram.
KN  – KiloNewton.
Km – Kilometer.
ISRU – In Situ Resource Utilization.
OSAM – In Orbit Servicing, Assembly, and Manufacturing.
OSCAR – The Orbital Syngas/Commodity Augmentation Reactor.
SSPD – Satellite Servicing Projects Division.
NASA – National Aeronautics and Space Administration.
JAXA – Japan Exploration Space Agency.
ESA – European Space Agency.
ESI Era of Space Industrialisation.
DARPA – Defense Advanced Research Projects Agency.
RSGS – Robotic Servicing of Geosynchronous Satellites.
CMG – Control Moment Gyros.
MEV – Mission Extension Vehicle.
MEP – Mission Extension Pod.
PGT – Pistol Grip Tool.
SGT – Satlet Gripper Tool.
UGA – Universal Gripper anchor.
SPDM – Special Purpose Dexterous Manipulator.
SSRMS – Space station remote manipulator system.
LAW – Long Armed Worker.
KRM – Kerbal Robotic Arm.
RCS – Reaction Control System.
EVA -Extra Vehicular Activity.
ISS – International Space Station.
CSS – Central Servicing Station.
RSV – Remote Service Vehicle.
MSM* Manned Service Module.
RJB* – Retrieval JunkBot.
CATS -Cheap Access to Space.
OHP – Oscillating Heat Pipes.
HET – Hall Effect Thruster (Ion Thruster).
ULA – United Launch Alliance.
SLS – Space Launch System.
KSP – Kerbal Space Program.
MLI – Multi-Layer Insulation.
MBS – The Mobile Base System.
MSS – mobile servicing system.
PCBS – Polychlorinated biphenyl.
HDPT – High-Density Polyethylene.
HTP – High-Test Peroxide.
ALICE – Aluminum Oxide Rocket Fuel.
RTG – Radioisotope thermoelectric generator.
SDD* – Space Debris Database.
SCD* – Space Component Database.
EEG – Electroencephalogram.
VOR – Visual Object Recognition.
ARRMS* – Automated Recycling and Restoration Manufacturing Station.
FART* – Factory Activated RCS Thrusters.
EEC* – Some Engineering Necessary.
NEN*  – No Engineering Necessary.
ES* – Engineering from Scratch Necessary.
*Asterisk indicates project-specific terms.

– – – – – – – – – – – – – – – – – – – 

Building Out The Low Earth Orbit Ecosystem:
This section is new and will be edited several times during the next year, so please bear with me.

“Ecosystem” is the new buzzword for want-to-be mobster entrepreneurs, but what exactly is an ecosystem?  Believe it or not, Eco isn’t shorthand for economics (sarcasm).  It is taken from the Greek prefix eklos meaning home or family, or the extended family unit in a household.  It is used as a business term to mean an extended network where all organizations are affected by each other.  It is a great term when looking for business partners.  It is usually said with the implication that we will all get rich together.  When used as a business term, it is a gross misappropriation.  Eco is short for ecology.  How biological organisms interact with each other in unique environments with the implication that there is some natural stability.  There usually aren’t more than ten mammals in space at any time, which make up most of the weight by mass of every known living thing off planet. However, let’s see if we can focus on the environmental implications of the word as well as the financial.   

Let us start with the Mars Ecosystem.  There isn’t any because there is no life.  That is how most, if not all, ecosystems in space work.  Ok, ok, that is a bit heavy-handed. Let us look at it from that fintech standpoint.
  
“If there is an in-demand industry that can only be conducted in space, people and materials would need to get to and from space which would scale the launch industry, which would lower launch costs, which would enable more industries in space, which would then, in turn, scales the launch industry again, which would lower launch costs… etc. etc. etc.”  – Wendover productions.  

Wendovers Ecosystem represents an economic engine, and it already exists.  It consists of several thousand communications satellites.  Reconnaissance and other military satellites, the ISS, and all that currently exists in human space operations.  It also includes science endeavors and everything in space that isn’t interplanetary or geostationary.  However, it contains more debris than anything else.   Based on the internet of things, the demand for communications networks such as Starlink will increase, and all that Wendover productions explained applies.  As human exploration of the solar lsystem increases, such as Elon Musk’s financial vision of a Mars colony comes to fruition, there is a need for refueling and crew transfers, wherein the same Wendover rules apply.  This is not the recycling in a low-Earth orbit ecosystem, but it is a low-Earth orbit ecosystem and does provide a cost-reward comparison.  

In a recent lecture for the University of Austin about space debris, Moriba Jah was asked about the low Earth orbit ecosystem.  He was asked because the CEO of Redwire, Peter Cannito, mentions it when talking about Orbital Reef but fails to elaborate on what he is talking about.  I came across the term when working for a Fintech company in LA and had added it to the proposal before it was publicly mentioned.  I also didn’t have any elaboration.   Moriba appeared to have spent a few weeks thinking about it and wasn’t sure either.   He did offer one epiphany:  “Nature, when left to its own devices, seeks equilibrium.”

Recycling in the low Earth orbit ecosystem goes something like this.  The more we salvage and restore, the larger we can expand our operation, allowing us to capture and process debris faster.  This, in turn, allows us to build out manufacturing in low Earth orbit faster, capturing and processing debris faster while cleaning up space junk and preventing future catastrophes.  

There is too much debris in low Earth orbit.  Even if our math and engineering were perfect, and Donald Kessler’s prediction of a cascading destruction event in low Earth orbit never comes to pass. 

Moriba Jah’s Low Earth orbit ecosystem argument puts the debris as the predator and active satellites as the prey.  It is a stretch.  The analogy works better for the low-Earth orbit zombie apocalypse ecosystem, but it does make me want to giggle a bit. 

Nature will Equalize and create stability.  It will sort itself out, but not without major catastrophe.  It takes 60-100 years for most of the debris to naturally orbitally decay.  We offer dead satellites and miscellaneous debris new life and reincarnation in the form of another body, which completes the low Earth orbit ecosystem.  

The low Earth orbit ecosystem sounds fishy: Let us go with an aquatic theme.  Blue Origin chose Orbital Reef as its manned space station’s name.  Let us roll with the motif.  We are salvaging space debris, so we will take a fisherman’s perspective.   We seek to net hook or harpoon space debris to provide sustenance for the family (of aerospace companies).  When space debris mates, it creates many more objects to capture. Unfortunately, they are all too small to provide sustenance and never grow bigger.  

Environmental Opportunities: 

1968 Apollo 8 -William Anders.
Earth: Let ʼs start with the implied secondary mission directive, a greener planet. 

There is a whole section on terrestrial improvements at the bottom of this document, but we will cover some of the Yspace basics here.  We hope this project helps create and inspire technologies that help with recycling back here on the planet.  We can help increase awareness about climate change and significant impactors such as planned obsolescence.  We can reduce our footprint by shrinking the seemingly infinite amount of garbage currently created by daily living (4.5 lbs/day average per person).  We will make the world a more beautiful place to live in. 

The environmental movement started in 1969.  The first Earth Day was in 1970.  Perhaps even before that, with the election of Teddy Roosevelt. Humanity barely even knew about global warming yet.  It was about increasing the air quality in cities, conserving nature in rural areas, and conserving resources in urban areas.   Humans now produce over 1 billion metric tons of waste per year.

Hurricane Dorian and Andrew cost the US government over 25 billion dollars each.  Sandy cost 65 billion dollars.  Hurricane Katrina cost the Government 125 billion dollars. This project will not solve climate change.  It is already too late. However, we can limit the long-term effects.

This project would reduce carbon emissions by more than 12.5%, based on lowering materials transport and mining needs.  It also helps by raising public awareness of the issue.  Hopefully, this would create a more self-sustaining society better equipped to deal with the effects of climate change. 

I recently watched a short documentary on PBS called “How to survive a mini ice age.”  It was about an Alaskan tribe of Inuits from the 16th century in a village called Nunalleq.  It got very cold in the region, enough to dramatically reduce the food supply.  The tribe should have died off or migrated, but they didn’t.  Instead, they fiercely adapted and dramatically changed their diet, building materials, clothing, and so on for a few years.  The secret to their survival and ours is adaptability.  This project will make the country and perhaps the world more adaptable to change, more “EcoDynamic,” If you will.

We might get to Mars. We might not. Whatever the case, The Earth is the only planet we live on now.  A focus on waste reduction and climate change is becoming increasingly necessary here at home (Earth). “You use it; you lose it.”  Lastly, It will hopefully also help with the “we are all in this together” attitude required for any large-scale undertaking as a species. Is humanity a threat to the planet? No, not really.  Earth will be here long after humanity.  We are, however, a threat to ourselves.  The idea is that if we treat the Earth well, It/she will treat us well back.  The likely alternative is that we will prove Charles Darwin right by ruthlessly driving ourselves into extinction.  God might even give us an award.  We can solve climate change tomorrow with a good nuclear winter.

– – – – – – – – – – – – – – – – – – – 

Terrestrial Opportunities:

“Earth, will you marry me?”
Diamond Ring Earth Apollo 12

I am trying to use words that work but failing.  It might be impossible to convince the United States and the world to cut the crap.  Perhaps linking this Earth day 2021 video from Jane Goodall will at least get the message across better than I can convey now.  

For some, the ends are justified by the means.  For others, the means are included in the end.  These are two fundamental differences in manufacturing.  One version works on a baseline, while the other works on a bottom line.  

Faster, Faster, More More:  

There is a strong argument that you cannot fix this problem with tech.  Tech created the problem in the first place.   There is a good deal of truth to this line of reasoning.  The world goes faster and faster the more tech we produce.  With every new advancement comes more garbage, more waste, more junk, both physical and intellectual.  All of this might well be true.  The only solution may be less.  Just less of everything.  However, we are going to try anyway.    

It might be possible to turn back the garbage tide if we can intermingle financial conservatism with environmental conservation. Buy less crap, build less crap. Stress quality over quantity and, of course, recycle.

Adaptability:  

In “The Selfish Gene,”  Richard Dawkins argues that selfishness is the most important factor for survival.  The counter to this argument is from Neal Stephenson. Adaptability is the most important factor.  Arguing for adaptability is not an argument against capitalism.  However, it is an argument for self-reliance.  I look at space tourism as the selfish approach.  There are short-term gains with a high-risk factor and low long-term returns.  There is an easily relatable human factor, but meatbags are limited and expensive.   A space factory/repair dock/recycling station is about as adaptable as it gets, with a long-term gain and hopefully ever-increasing returns.

“The overview effect”:  A feeling Astronauts get when looking down on the Earth.  It fills them with a desire to protect and cherish the Earth.

Recycling:  American Industrial Green Revolution:  

Credit: Bruce Blackburn

Objectives:
1 American Industrial Self Reliance.
2 Collect Underpants (kidding).
3 A Carbon Neutral American Industry.
4 Reduction of waste.
5 Responsibility Accountability Mindset.
6 Common inspiration.
7 Advancement of technologies involving land reclamation.
8 Development of Microfactories for urban use.

It only takes one recycling project top down to make it a household word.  This project aims to show that it is a great move for the space industry.  I truly believe that it is.  The secondary effect would be more immediate.  While we work to develop the technologies necessary to make this happen, it will occur to a large portion of the population, including current big business and manufacturing, that this is also a great idea for us right now, on this Earth.  Here are the 2022 EPA Guidelines.

The first problem is greenwashing.  This is when companies pretend to be eco-friendly but aren’t.   The best example is the recyclable logo put on most packaging.  Often, there aren’t any facilities currently that can actually recycle the product.  It also happens when companies like Walmart claim zero carbon emissions when they produce more waste than most nations and burn more fossil fuel importing products than an airline company.   It is easy to single out Walmart, but it is a systemic and commonly practiced business move, endemic throughout all industries.  

Greenwashing and offsetting carbon emissions:  There are no words to describe how the carbon tax system is panning out.  I had a bad feeling about it.  Sometimes, it sucks to be right.  Corporations are paying rich people not to cut down trees that they had no intention of cutting down anyway, which ends up having a net minus effect on the environment.  You can’t make this stuff up. –John Oliver

Unfortunately, recycling isn’t up to the consumer.  It is up to the manufacturers.  Corporations pretend it is in your hands, but it isn’t.  It is time to take the higher ground.  It won’t work any other way.  Recycling needs to be profitable for industry. The processes need to be streamlined, and we must improve significantly.  Reduce, reuse, restore, and recycle.

Recycling has been around since the dawn of civilization.  Some ancient cultures, like the Greeks, melted down their statues for weapons and back again into statues.  During WW2, America recycled almost everything, down to rags and bones, and it worked.  Even the Coca-Cola corporation recycled 80% of its bottles in the 1930s.

According to the Albany Times Union, The Covid pandemic and its disruption of some global shipping caused a spike in the cost per pound of recycled plastics, allowing Ulster county NY to turn a profit for the first time.  The city doesn’t have a recycling plant but was able to sell its plastic garbage to brokers for a profit.  It shows that the margin for profit might be closer than one might think.

Recycling almost anything from water to steel has a cost versus profit which is strictly a matter of the cost of energy production.  The more energy we can provide, the more efficiently we recycle things.  This is universal.  It applies both to this space project and recycling back on Earth.  

A focus on recycling will benefit everyone alive today and the next few generations too. Maybe it buys us a few more hours, perhaps a few more days, years, etc. However much time we gain, it is a massively good investment for the Earth’s population. 

I spent a good deal of time driving for Uber and Lyft.  They keep drivers on the road by offering incentives to drive at certain times, do several rides in a row, or go to a specific area.  They have successfully gamified my old job.   It would not be hard to gamify recycling.  There is already an incentive via cash rebate for tin cans, but perhaps more can be done.

Y2space?  A big part of the project is about making recycling cool, not just necessary, like going to the doctor, but genuinely fashionable. In American culture, there is a stigma against it.  People are in love with new things.  People are in love with convenience, from our plastic packs to the shirt on our backs. However, the gears of industry can grind forward without turning the planet into an inhospitable trash heap, but first, it needs to be cool.  It needs to be cool for big business cattle ranchers and coal miners. Cool for the superstore employees and fast food workers too.  Cool for the ultra-wealthy and ultra-poor, respectively.  The only solution for making recycling and environmental conservatism cool for everyone, red, blue, purple, black, white, yellow, brown, rich, or poor, is a top-down mega solution.  Something people can get behind, something that shows the truth in action, something that truly inspires awe.

At the Las Vegas garbage dump, they actively mine methane.  The methane powers 11,000 homes in southern Nevada.  The whole concept makes natural gas mining look backward.  Natural gas is not a bad alternative to coal, but why mine anything when we have so much garbage to burn?

I imagine robotic garbage worms, landfill mining robots that find specific high-value things in a landfill for recycling. They could turn the dump into a literal goldmine.   They are using a type of trash-eating robot to clean up the oceans.  It involves a long tether that sits on the surface and slowly drags the trash into a barge.  So far, it has been very effective.  I am not sure how such a machine would be made to sort garbage in a landfill, but where there is a will, there is a way, especially since covid probably stopped your sense of smell.     

There have been recent breakthroughs using microorganisms for extracting precious metals from E-Waste.  This is the popular solution currently for landfills.  

A few lucky small cities on train routes could become massive recycling, manufacturing, and waste-to-power energy hubs.  Large-scale recycling and manufacturing would help revitalize America’s industrial sector. Things built in America with American materials. Perhaps Butte, Montana, Wichita, Kansas, or Sioux Falls, South Dakota.  Since they closed the Freshkills landfill in Staten Island, NYC has an enormous trash problem.  I used to work for NY State and could see them put in a bid for a recycling factory in western NY.  Imagine countrywide complaints about the smell as the trash train rolls from town to town.

ExxonMobil made 100 billion dollars net with single-use plastics in 2020.

Another way to stop the debris problem is to stop launching things into space

Recycling is the first step to conservation. If you cannot see it happening, if it is thrown away and forgotten, then you cannot make any progress toward other lofty goals, such as climate change.   Well, you can, but only through big industry, not on a citizen level.  

Sorting: American recycling factories all seem to have the same problem.  They require too many people to manually sort garbage in a human assembly-line system.  Like it is 1920 or something.  A few fairly modern European facilities reduce the need for labor, but it is still a problem.  This project will overcome the main cost of recycling which is labor costs.

Single-stream recycling: sounds great; put all the stuff into one container.  Simplicity for the consumer is what we are aiming for.  However, at the Pittsburgh Nevins plant and many other cities in the US, it starts with a person in a bulldozer unloading the trash manually onto a conveyor, then a team of people removes non-recyclable material also by hand.  They do use some automation to remove the paper, Aluminum tin, and plastic products.

Duty Cycle:  

No, not that duty cycle.  Duty cycle is an engineering term used when building things.  The longer the duty cycle, the longer the object is meant to last.  For example, a door hinge has a virtually unlimited duty cycle.  Cars and computers are meant to last 10-20 years.  Phones last between 1-4 years.  However, the wrapper for your snack pack’s duty cycle is one-use only.  Recycling is great, but it is also important to build things with a much longer life expectancy and reuse in mind.  

Sorting Garbage:   

The highest cost of recycling is the sorting process.  In many ways, this problem requires a great technological leap in the de-manufacturing process.  In order to cut down on the labor intensity of terrestrial recycling,  we hope to start the station-building process with an unmanned robotics bay.  

Sorting garbage is not cold fusion.   It is currently expensive in terms of human labor cost, but it shows a great deal of promise in the new world of artificial intelligence robotics and computers.  In many ways, this is the project from the seventies that can provide the most significant lifestyle and efficiency improvements.

Toxic Sludge:   

Climate change is only one part of the equation.  Humanity’s inability to properly dispose of waste has historically led to tough living conditions, with a massively lowered lifespan for people living in urban conditions.

Air Quality:  

I am going to be honest.  Recycling is an industrial process.  Chances are this will have a negative effect on air quality. Since we know this from the onset, part of the terrestrial aspect of this project is to address and eliminate the issue.  Air quality is a fundamental concern for the department of energy already. There has been amazing progress for natural gas and coal plants.  There is a new technology being pushed hard by Koch Industries, which seems to be parroting me in a good way.  Maybe I am parroting them.  It is hard to say.  They have made a serious commitment to waste-to-power.  Air quality is the main concern with waste to power, recycling refineries, or even something as clean burning as a solar furnace.  I am not a supporter of the concept of Innovation through regulation, but in the spirit of the project, that might have to happen.  Covid absolutely sucked, but it was nice to be able to see the mountains clear as day in Las Vegas from my apartment.

Waste to Power:  

The project will shed new light on current recycling operations and waste-to-power plants.  We need to get better at it quickly. It will guide a terrestrial green industrial revolution.

In the U.K., They converted a coal plant to recycled wood chips.  It puts out around 3500 MW and powers a good portion of the city of London.  They also have several waste-to-power plants set up across the country, which is smaller scale but more adaptable.  In the United States, Koch Industries, of all companies, has built several waste-to-power plants across the country.  They seem committed to recycling and, in their words, ‘environmental stewardship.’  There have been complaints that their plants aren’t very adaptable, and they end up cutting trees down to run them to keep them running.  Hopefully, their waste-to-power system will improve dramatically in the coming years.

Imagine a clean-burning trash can Incinerator that provides power and heats your home, something around the size of Mr. Fusion from Back To The Future.  I live in a city.  There is no space for composting.  Sure, an Insinkerator could help make smaller trash bags. That would be nice.  However, I buy as much packaging by weight as food at the grocery store.  We can’t make a clean-burning personal power production with a waste disposal incinerator small enough yet “Minisin,” but that is the sort of tech we hope this project can help manifest.  Currently, only 8.7% of the plastics used in the United States are recycled.

We could build a waste-to-power plant that runs by incinerating money.  They say that money = power.  (this is a joke about the green premium).

Urban Waste Management:

In order to make the system adaptable enough to handle the immense variety of garbage,  we are attempting to create a universal recycling technology with the ability to shred, sort, and compact a large amount of garbage.

Micro recycling technologies would allow for facilities operated in urban locations.  A multipurpose recycler shredder could be made for studios and one-bedroom apartments where there might not be space.

The micro shredder could be easily transportable for easy deployment in rural industrial areas, which would also prevent trash transportation and energy expenses.  We aim to create easily deployable improvements in garbage sorting accuracy, speed, and automation.

It could take the form of large bins where you put your cans.  It powders the aluminum on the spot or just grinds it to dust to be sorted later by robotic sorting machines, such as those used at the Las Vegas Trash Dump.  It might also pay people for the materials.) The result is greater manufacturing efficiency.

There are other more human-oriented solutions.  Goodwill does a good deal of sorting and recycling.  Millions of pounds of E-waste, books, and textiles, their recycling program sorts things at the end of their retail life into 11 categories for recycling.  Perhaps The KHOR corporation business model can be augmented to include recycling more traditional waste.

Our work in the service bay could lead to a very different type of improvement, such as the automatic auto-mechanic, a robotic car repair facility.

One day, while watching a group of people in Los Angeles doing aerial acrobatics trying to get a branch out of a powerline, the idea of flatbed utility trucks with a robotic arm for auto-arboring and roofing.  A drone launches and maps a 3D terrain model and works out viable programs for cutting tree branches and other repairs.

Robotic servicing technology could help in places like the ship scrapping facilities in Alang, India, where the patron goddess is kali. Adaptive intelligent robotics would bring a degree of safety and efficiency to a dangerous workplace.

The robotic nature of the project could help revolutionize deep water robotic welding construction and repair or nuclear waste storage and disposal.

There is an added fossil fuel cost of exporting waste on top of the fossil fuel cost of importing goods.   We will likely see electric-powered autonomous garbage trucks picking up garbage and recyclables in a few years.   It will still cost electricity to move waste, but at least they won’t be using fossil fuels. 

Turning landfills into graveyards:  They often build residential housing or public spaces on top of landfills.  Unfortunately, It isn’t safe or healthy.

Jokes: 

Death, Taxes, and now Recycling too.

Somewhere in the universe there is a Jawa mothership made from scrap.

A whole new meaning for the term vacuum cleaner.

In space, no one can hear you clean.

We are done trying to explain things.  Now we are Ysplaining.

Yspace supports STEM.

Yspace has wings.

Yspace supports trees.

Yspace would like to branch out.

Yspace supports Vertical integration.

Yspace’s assets include a divining rod.

Y ask why; try recycling in space without a chemical additive process.

If New York buys YSpace, it would be NYSpace.

If the Planetary Society buys YSpace, it would be Nyespace.

If my name were Tom, it would be Myspace.

Y space knows how to shunt.

Y= <3 space.

The sailors call us Y’ay space or yay space.

As we get older, we might become Wise Space.

If Apple Bought YSpace, we would be Woz Space.  

If Privateer bought YSpace it would be Rspace

We also have a flux capacitor.

If Asians buy the project, we can make the station look like a Junk (square boat). For a lark, check out the late 1980ʼs Dungeons and Dragons Spelljammer Dragon Ship.

Something about space junkies. 

Skunkworks has agreed to develop F.A.R.T. .

Rubber room for space tourism and wall-to-wall trampolines.

Harmonium is an ammonia hydrogen Radon gas mixture.

Company name: YSpace. (If we partner with SpaceX, we would be the axis of space evil)

Fixing Bicycles does not make you a recyclerist, but it is a good start.

Using a pressure washer to propel a pilot and an office chair in reverse down a hallway might not help clean up space debris.   Heck, it might not even help clean the hallway, but it sure is fun.

Math Engineering Technology Highlights. (METH).  Please don’t do meth.  Life can get very unfunny fast.

True Story, One night, while working for postmates (now Uber Eats), I did the White Kessel run in under 14 parsecs. 

 Cubans are square.

Texas: Steers, Queers, and Aerospace Engineers.

I am rewriting the entire document and taking out all the ifs, ands, or buts.  

If you cross your eyes, sometimes you can see the dot’s on your t’s.

Hackovsky – The Netcracker

Obiconisdom

Pulling carbon from the atmosphere to make fizzy drinks.  

Pulling carbon from the atmosphere to make dry ice.

A guide for how to get that fictional NASA janitor job.

Hi, I work for NASA. Would you like fries with that?

This project involves a hardcore satellite-on-satellite action and is unsuitable for ages 17 and under. 

In space, the homeless ask for 100 million at a time.

Watch your Gluon intake, That last joke quarks me up

I am creating more space junk just by writing this.

Whoever said there is no competition in space is smoking the orbital reefer.

My Pewmatic tube

Carl Sagan Versus Karlshagen

Holy diver, military satellite de-orbiter. “you’ve been down too long in the midnight sea”

If the headquarters were built on tribal land we would be called Howspace (Alonzo and Tinoco Tribal Spaceports.)

Go Kick Rocks, asteroid mining joke

Space scrabble https://www.nasa.gov/seh/appendix-a-acronyms

Pizza Hut has just copyrighted and trademarked the pie chart.

Taco Teleportation

LOX is much more expensive per Kilo as smoked salmon.

Universities are where people study the universe.

*Father Guido Sarducci, People’s Space program (1980) https://youtu.be/iTHpChltQzI?t=1610

– – – – – – – – – – – – – – – – – – –

Where are we now?

This project was built with different priorities in mind at different stages.
The first objective was to prove the viability of recycling in space.  
I feel this objective has been reached.

The second objective is to accurately calculate costs as well as potential profit.  The project doesn’t quite accurately fulfill this objective enough to properly progress to the third objective.

The third objective is to create a timeframe and design plan for the actual station construction  The dataset is known as a SEMP.  Some steps have been taken to accomplish this.  However, this step seems to require a formal education focusing on management, engineering, and accounting.  YSpace will be taking applications as soon as possible.

Driven to do the impossible:   

Let us talk for a second about SpaceX vs. blue origin or ULA.   How does SpaceX keep rocking price points, leaving other companies in the dust?   The theory goes something like this.  They are trying to colonize Mars.  This is an impossible task.  Since it is so impossible, it makes doing hard things look simpler.   All of a sudden, putting a crew on the ISS looks easy.  100t to LEO is no big thing.  Man on the moon?  Heh, no problem.   If you start out trying to do something impossible, you might succeed, you might fail, but you also might more easily overcome some of the harder tasks along the way.   I feel that this space recycling project would achieve similar results.    Asking for a recycling station could pave the way for a plethora of things that we need but aren’t smart enough to ask for. 

Next Steps: 

It is time for someone else’s excellent idea. What is our factory building? We are building custom parts for a quick turnover in our satellite servicing and repair project, but that probably wonʼt take anywhere near all our resources. Maybe a space station for servicing people rather than satellites, perhaps a colossal spacecraft to Mars.  A lunar colony? Asteroid Mining? Manufacturing a thin aluminum Solar shade? Space elevator? Beautiful rainbow unicorn starships with Nyan cat drives?  Whatever the next step is, this project will help with it.

About the Author:
Hello there!  Thank you for taking the time to read this.  My name is Jacob Bouchard.  I grew up in New York City and the surrounding areas.  I currently live in Las Vegas.  I received a bachelor’s in art from Bennington college in the year 2000. Bennington had a strange art-driven curriculum.  It focused on the process of learning and creativity, as opposed to history and technique.  This was done for the sole purpose of trying to create new things and new ideas.  Let us hope I made good on it.  Afterward, I studied photography and graphic design at the School of Visual Arts.  Honestly, I had some skills but was never very good at them.  I spent some time working for the New York State Senate doing research and policy.  I was better at that.  The job ended.  I fell on hard times and was forced to move to Las Vegas, where I got a job working for Comcast doing internet tech support.  It was a normal day in August 2017.  I finished the night shift and went to bed around 2:00 AM.  I had an insane dream about this project. I woke up and did a couple of searches online, landing on the DARPA website and staring at something I saw in the dream.  Crazy, but true.  Since then, I have been writing this proposal.  I have taken several online classes, including math, science, engineering, accounting, and writing.  I read a bunch of books and watched a ton of space news.  Hey, I know I am not the perfect person for the job, but several years on, it is starting to shape up.  It might not be there yet, but this is by far the best document I have ever written, not that I have even written much.   It gets better every year.

By: Jacob Bouchard