Dynamics Simulation of a Small Satellite with a Robotic Manipulator for Additive Manufacturing

In-space manufacturing is an emerging concept that offers several benefits when compared with traditional space structures that are built on the ground and launched fully assembled. Structures manufactured in space are not limited by launch vehicle fairing volumes and do not require reinforcement to survive the ascent to orbit. Additive manufacturing is uniquely suited to this paradigm and has been proposed as a key piece of several in-space manufacturing architectures. However, the complex dynamics involved with 3D printing a structure on-orbit require additional study. Controlling a spacecraft with an attached multijointed, independently articulated robot arm is a complicated problem, and additive manufacturing is especially difficult due to the large tool paths required to complete a structure. Here, a numerical model of a free-flying small satellite with an attached robotic arm assembly is presented. Simulations for multiple 3D structures printed on-orbit and analysis of the small satellite controls required to stabilize the articulated arm are described. Multiple spacecraft control strategies are implemented, with resource utilization tracked throughout the simulation. The results demonstrate the feasibility of a small satellite platform for hosting a 3D printing robotic arm in space, and the simulation can be used to inform the design of future small satellite systems attempting complicated on-orbit manufacturing missions.