SBIR-STTR Award

In-Space Assembly and Manufacturing Using Synchronized Robotics
Award last edited on: 3/26/2023

Sponsored Program
SBIR
Awarding Agency
NASA : MSFC
Total Award Amount
$873,372
Award Phase
2
Solicitation Topic Code
Z3.04
Principal Investigator
Babak Raeisinia

Company Information

Machina Labs Inc

9410 Owensmouth Avenue
Chatsworth, CA 91311
   (770) 769-0114
   info@machinalabs.ai
   www.machinalabs.ai
Location: Single
Congr. District: 37
County: Los Angeles

Phase I

Contract Number: 80NSSC20C0356
Start Date: 8/12/2020    Completed: 3/1/2021
Phase I year
2020
Phase I Amount
$124,679
Articulated robots are being entrusted with an ever-increasing range of manufacturing operations across various sectors. This is stemmed, among other factors, by the broad movement range, flexibility, and small footprint of these robots. However, when it comes to high-payload operations, gantry robots, with their rigid construct, are still the option of choice. This is particularly true when precision is of concern. Unfortunately, a rigid gantry setup is difficult to implement in space especially considering weight constraints and the need for flexibility. Modular robotic kinematic systems offer process flexibility and diversity. Robotic kinematic systems are already being used for in-space applications. This proposal is aimed at developing a machine learning-based software solution that would allow for high-precision, high-payload manufacturing operations to be carried out autonomously using multiple articulated robots. The work targets robotic sheet metal forming, which given its versatility and simplicity is an ideal operation for both on-ground and in-space manufacturing/repair of metal parts. The robotic forming cell consists of two heterogenous, 6-axis robots mounted on two linear tracks and a real-time monitoring and control system. The robots must work in coordination with each other to incrementally form a sheet of metal into a part based on an input CAD file. This work introduces a software solution which addresses a number of challenges. First, both robots need to be synced while experiencing differing loading conditions imposed by the forming operation (e.g., due to variation in friction). Second, the positioning of the two robots need to be dynamically adjusted to make sure the overall compliance of the robotic system is minimized. Third, the system monitors the forming operation in real-time and assesses its deviation against the initially defined path. The feedback from the monitoring system needs to be actively used to update the predefined path. Potential NASA Applications (Limit 1500 characters, approximately 150 words) First, the developed software modules and control strategies can be adopted to enable autonomous in-space manufacturing and on-orbit assembly operations. Second, the robotic cell can be used to manufacture lightweight parts for various NASA programs (e.g., components for solar arrays, lander systems, and ultra-lightweight dewars). Third, the forming technology can be adopted for in-space manufacturing and in-situ resource utilization (e.g., repurposing metals from spacecraft to manufacture structures or molds to build habitats). Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words) The robotic forming cell will be used to manufacture and supply sheet metal parts to a multitude of industries (e.g., aerospace, automotive, energy, architecture). The system allows for rapid iteration over design/material at reduced time and cost. It also enables fabrication of parts with previously impossible-to-achieve performance. Composite mold fabrication is an application of the technology.

Phase II

Contract Number: 80NSSC21C0505
Start Date: 8/5/2021    Completed: 8/4/2023
Phase II year
2021
Phase II Amount
$748,693
Ground-based manufacturing processes are traditionally not designed with resource constraints and versatility in mind. Single-purpose, heavy machineries are commonly used to carry out a single operation in a long chain of operations. They are, for most part, not autonomous in that they do rely on skilled labor for continued operation and quality assurance. These are all luxuries that cannot be afforded in space. However, the know-how in these manufacturing processes and the processes themselves are essential to success of NASA in extending its presence into deep space. Sheet metal forming is one of such processes where in its current form, it is not ready for deployment in space. Sheet metal parts are, however, extensively used in a multitude of applications, making their processing an enabler for deep space travel. The aim here is to take an established on-ground manufacturing process and make it more accessible to NASA for both its ground-based and in-space applications. Through our Phase I work, we demonstrated the viability of two-robot, sheet metal forming system for NASA and non-NASA applications. A number of modules were developed to allow a flexible system that can form complex parts but also one that can manipulate an existing part for reworking/repair/repurposing. The flexibility of the system is enabled by an integrated metrology system, the feedback of which is used for control and analysis. Work on maturing the robotic system is planned for this Phase II. Specifically, work is planned to increase the autonomy of the system through advanced controls and learnings from collected data. Additionally, this Phase II will target manufacturing of tanks. Various sizes/shapes of tanks will be prototyped. As for large tanks, work with Michoud Assembly Facility is planned to manufacture a large toroidal tank. Necessary characterization and testing is planned, laying the groundwork to establish a versatile route to manufacture different tanks for NASA. Potential NASA Applications (Limit 1500 characters, approximately 150 words): First, the developed software modules and control strategies can be adopted to enable in-space manufacturing and on-orbit assembly operations. Second, the robotic cell can be used to manufacture lightweight parts for various NASA programs (manufacturing of tanks is explicitly treated here). Third, the forming technology can be adopted for OSAM and in-situ resource utilization (e.g., repurposing spent upper stages to manufacture structures or molds to build habitats). Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): The robotic forming cell will be used to manufacture and supply sheet metal parts to a multitude of industries (e.g., aerospace, automotive, energy, architecture). The system allows for rapid iteration over design/material at reduced time and cost. It also enables fabrication of parts with previously impossible-to-achieve performance. Composite mold fabrication is an application of the technology.