IP Library › Granted Patent US 12679028
Granted Patent B2
US 12679028 · App. 18/908,308 · Granted Jul 14, 2026

In space assembly

Inventors: Thomas W. Murphey (Fort Collins, CO); Carter Fortuin (Fort Collins, CO)
Assignee: Opterus Research and Development, Inc.
B29C64/209B29C64/165B64G1/2225B33Y10/00B33Y30/00
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Quick Facts
Patent No.
US 12679028
App. No.
18/908,308
Granted
Jul 14, 2026
Kind
B2
Abstract

A method of in-space assembly includes: providing a roll of spooled high strength composite (HSC) boom, a robotic arm, and a printhead disposed at about an end of the robotic arm, the roll of spooled high strength composite boom feedingly coupled to the printhead; positioning the robotic arm; dispensing from the roll of spooled high strength composite boom a length of high strength composite boom; positioning again the robotic arm; dispensing another length of high strength composite boom from the roll of spooled high strength composite boom or from another roll of spooled high strength composite boom; joining by the printhead; and repeating said step of positioning to said step of joining until a desired structure is assembled in part or in whole. A system for in-space assembly and printhead to print struts for in-space assembly are also described.

Claims (18)

1 . A system for in-space assembly comprising:

at least one robotic arm;

at least one HSC boom dispenser;

at least one printhead mechanically coupled at about an end of said at least one robotic arm, said at least one printhead feedingly coupled to said at least one HSC boom dispenser, said at least one printhead to join two or more dispensed lengths of said at least one HSC boom dispener, said at least one printhead fed by a feedstock of a spooled high strength composite boom of said at least one HSC boom dispenser; and

wherein said at least one printhead joins two or more lengths of the at least one HSC boom dispenser as part of an in-space assembly of a structure.

2 . The system of claim 1 , wherein said at least one robotic arm comprising an arm position set by a combination of twisting and bending.

3 . The system for of claim 1 , wherein said spooled high strength composite boom comprises a braided thin-ply tape.

4 . The system for of claim 1 , wherein said spooled high strength composite boom comprises a reinforcement layer affixed on one or both sides of a compressed and bent HSC boom joint area.

5 . The system for of claim 1 , wherein said at least one HSC boom dispenser provide a plurality of lengths of high strength composite struts.

6 . The system of claim 5 , wherein said structure comprises a tensioned aligned antenna structure.

7 . The system of claim 5 , wherein said structure comprises a solar array.

8 . The system of claim 5 , wherein said structure comprises a parabolic mirror or a parabolic reflector.

9 . A printhead to print struts for in-space assembly comprising:

a printhead frame; and

two or more feedstock wheels feedingly coupled to said printhead frame to accept a feedstock sleeve from a HSC boom dispenser.

10 . The printhead of claim 9 , further comprising a shear mechanically coupled to said printhead frame to cut lengths of struts.

11 . The printhead of claim 9 , further comprising at least one holding and fusing clamp to form ends of printed struts and to join formed printed struts to together to build a structure.

12 . The printhead of claim 11 , wherein said fusing clamp comprises fusing by a thermo bonding.